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Spray Freeze Drying Equipment Unlocking Growth Potential: Analysis and Forecasts 2025-2033

Key Insights

The spray freeze drying equipment market is experiencing robust growth, driven by increasing demand across various sectors, including pharmaceuticals, biotechnology, and food processing. The market size in 2025 is estimated at $500 million, projected to grow at a Compound Annual Growth Rate (CAGR) of 8% from 2025 to 2033. This growth is fueled by several key factors. Advancements in spray freeze drying technology, leading to improved product quality, higher yields, and reduced processing times, are significantly impacting market expansion. Furthermore, the rising prevalence of biologics and the increasing demand for stable and high-quality pharmaceuticals are major drivers. The pharmaceutical industry, in particular, is adopting spray freeze drying for the production of heat-sensitive drugs and vaccines, boosting market demand. Growing investments in research and development, coupled with the rising adoption of advanced analytical techniques for process optimization, further contribute to market expansion.

Several restraints exist, however. High initial investment costs associated with spray freeze drying equipment can hinder adoption, particularly among small and medium-sized enterprises. Also, the complex process and the requirement for specialized expertise in operating and maintaining this equipment pose challenges. Despite these restraints, the market is segmented by equipment type (lab-scale, pilot-scale, and industrial-scale), application (pharmaceuticals, food, and others), and region (North America, Europe, Asia Pacific, and the Rest of the World). Companies such as Meridion, GEA, IMA Group, Pilotech, and others are key players shaping the market landscape through technological innovation and strategic partnerships. The competitive dynamics are characterized by ongoing efforts to enhance equipment performance, expand product offerings, and increase market penetration. The long-term outlook remains positive, driven by ongoing technological advancements, increasing demand for high-quality products, and growing investments in the healthcare and food industries.

Keywords:

Spray freeze drying equipment

Beyond Traditional Methods: Novel Granulation Approaches for Enhanced Functionality in Pharmaceuticals

Ch. Niranjan Patra*, Supriyo Satapathy, Shuvendu K Dinda, Sudarsan Behera, Sashank S Hota, Goutam K Jena and Sanjiv K Panda

Abstract

Granulation, a cornerstone process in many industries, has seen significant advancements in recent years. This abstract explores these novel techniques, highlighting their potential to improve the functionality and efficiency of granule production.The traditional wet and dry granulation methods are addr essed, outlining their limitations, such as solvent usage and challenges with moisturesensitive materials. The abstract then delves into innovative approaches that address these limitations. Techniques like pneumatic granulation, reverse granulation, foam granulation, steam granulation, and moisture-activated dry granulation (MADG) are discussed, emphasizing their advantages. Foam granulation offers improved binder distribution and reduced water requirement, while steam granulation eliminates organic solvents and promotes faster drying. Improved granule properties, including folowability, compressibility, and controlled release characteristics, are highlighted. Additionally, the reduction of solvent usage and drying times translates to increased environmental sustainability and production efficiency.The abstract concludes by emphasizing the ongoing development of novel granulation techniques. It underscores the potential of these advancements to revolutionize various industrial processes, particularly in the pharmaceutical industries, by ensuring the production of high-quality granules with improved functionality and at a reduced environmental cost.

Keywords:

moisture-activated dry granulation, freeze-drying

Full Density Powder Metallurgical Cold Work Tool Steel through Nitrogen Sintering and Capsule-Free Hot Isostatic Pressing

Anok Babu Nagaram, Giulio Maistro, Erik Adolfsson, Yu Cao, Eduard Hryha and Lars Nyborg

Abstract

Vanadis 4E (V4E) is a powder metallurgical cold work tool steel predominantly used in application with demand for wear resistance, high hardness, and toughness. It is of interest to have a processing route that enables full density starting from clean gas-atomized powder allowing component shaping capabilities. This study presents a process involving freeze granulation of powder to facilitate compaction by means of cold isostatic pressing, followed by sintering to allow for capsule-free hot isostatic pressing (HIP) and subsequent heat treatments of fully densified specimens. Citation: Nagaram, A.B.; Maistro, G.; Adolfsson, E.; Cao, Y.; Hryha, E.; Nyborg, L. Full Density Powder Metallurgical Cold Work Tool Steel through Nitrogen Sintering and Capsule-Free Hot Isostatic Pressing. Metals 2024, 14, 914. https://doi.org/ 10.3390/met14080914 Academic Editor: Andreas Chrysanthou Received: 17 June 2024 Revised: 31 July 2024 Accepted: 2 August 2024 Published: 12 August 2024 Copyright: © 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). The sintering stage has been studied in particular, and it is shown how sintering in pure nitrogen at 1150 ◦C results in predominantly closed porosity, while sintering at 1200 ◦C gives near full density. Microstructural investigation shows that vanadium-rich carbonitride (MX) is formed as a result of the nitrogen uptake during sintering, with coarser appearance for the higher temperature. Nearly complete densification, approximately 7.80 ± 0.01 g/cm3, was achieved after sintering at 1200 ◦C, and after sintering at 1150 ◦C, followed by capsule-free HIP, hardening, and tempering. Irrespective of processing once the MX is formed, the nitrogen is locked into this phase and the austenite is stabilised, which means any tempering tends to result in a mixture of austenite and tempered martensite, the former being predominate during the sequential tempering, whereas martensite formation during cooling from austenitization temperatures becomes limited.

Keywords:

cold work tool steel; freeze granulation; sintering; capsule-free hot isostatic pressing; full densification

Advances in Spray-Drying and Freeze-Drying Technologies for the Microencapsulation of Instant Tea and Herbal Powders: The Role of Wall Materials

Júlia Mazár, Krisztina Albert ,Zoltán Kovács , András Koris, Arijit Nath and Szilvia Bánvölgyi

Abstract

The microencapsulation of tea and herbal extracts is gaining considerable attention in the food industry, particularly in the production of instant powders. This review examines the application of spray-drying and freeze-drying technologies for the encapsulation of bioactive compounds, focusing on the role of wall materials. Over the past two decades, carbohydrate-based (e.g., maltodextrin), gum-based (e.g., gum Arabic), and protein-based (e.g., whey protein isolate) materials have been widely used due to their impact on sensory properties, stability, protection of bioactive compounds, and other critical attributes of encapsulated products. Despite their widespread use, these materials have distinct advantages and limitations, such as cost, availability, and compatibility with different extracts. This review provides a comprehensive analysis of their physical and chemical properties, examines alternative and emerging wall materials (e.g., beta-cyclodextrin, sodium alginate, and inulin), and highlights the potential of combining different materials to optimise encapsulation outcomes. It also identifies current research gaps and future directions to improve the efficacy and quality of encapsulated tea and herbal powders.

Keywords:

microencapsulation; spray-drying; freeze-drying; wall material; core material; instant herbal powder; instant tea powder

METHOD FOR PRODUCING GRANULES, METHOD FOR PRODUCING NITRIDE CERAMIC SINTERED COMPACT, AND GRANULES

Inventors
高浪　健太郎 TAKANAMI, Kentaro
宮本　翔子 MIYAMOTO, Shoko
伊藤　和弘 ITO, Kazuhiro
矢久保　怜奈 YAKUBO, Reina

Abstract

Provided is a method for producing granules comprising granulation of a slurry containing a nitride ceramic powder, a sintering agent, an aqueous solvent and an organic additive by spray freeze granulation drying.

Binder Jetting Additive Manufacturing of Ceramics: Feedstock Powder Preparation by Spray Freeze Granulation

Wenchao Mark Du, Guanxiong Miao, Lianlian Liu, Z.J. Pei, Chao Ma

Abstract

Objective of this study is to prepare the binder jetting feedstock powder by spray freeze drying and study the effects of its parameters on the powder properties. Binder jetting additive manufacturing is a promising technology for fabricating ceramic parts with complex or customized geometries. However, this process is limited by the relatively low density of the fabricated parts even after sintering. The main cause comes from the contradicting requirements of the particle size of the feedstock powder: a large particle size (> 5 μm) is required for a high flowability while a small particle size (< 1 μm) for a high sinterability. For the first time, a novel technology for the feedstock material preparation, called spray freeze drying, is investigated to address this contradiction. Using raw alumina nanopowder (100 nm), a full factorial design at two levels for two factors (spraying pressure and slurry feed rate) was formed to study their effects on the properties (i.e., granule size, flowability, and sinterability) of the obtained granulated powder. Results show that high pressure and small feed rate lead to small granule size. Compared with the raw powder, the flowability of the granulated powders was significantly increased, and the high sinterability was also maintained. This study proves that spray freeze granulation is a promising technology for the feedstock powder preparation of binder jetting additive manufacturing.

ASEPTIC SPRAY FREEZE DRYING AS A TOOL FOR SUPPLY CHAIN FLEXIBILISATION

F. Kongoli, S. Buchmann, G. Imanidis, I. Karim, G. Kimura, G. Knipp, M. Makanga, N. Menshutina, P. Swaan, M. Tanner, H. Tarabishi

Abstract

Spray Freeze Drying (SFD) is an innovative lyophilization technology that is now entering industrial applications in lab, pilot and manufacturing scale for aseptic processing in pharmaceutical applications, as well as for the areas of medical devices, diagnostics and fine chemicals.

SFD applies the bulkware concept from solid dosage form processing to the area of aseptic freeze drying. It yields in highly homogeneous, free flowing bulkware which can be stored and accurately dosed. Filling is done after lyophilization, with a high degree of flexibility regarding dosing, primary packaging device design and unit number.
Accordingly, the supply chain becomes highly flexible and allows for patient centricity by even providing personalized medication, but also by bringing the required medication to the market or patient very fast.

In addition, product innovation potential is achieved by e.g. enabling to process high solid concentrations up to 40%, with still fast reconstitution characteristics of the lyophilized product. Furthermore, it allows for combinatory products by filling the various lyophilized compounds as required.

Many approaches have been taken to freeze material into particles for subsequent drying under cold condition. From dripping liquids directly into liquid nitrogen [1] to spraying in an cold air flow [2, 3].

The bulk freeze drying process can be carried out at atmospheric pressure (e.g. in a fluidized bed), in conventional freeze-dryers as a layer in trays, which are positioned on the shelfs or as shown here in a dynamic system with continous mixing to provide effecient mass and heat transfer. Drying at atmospheric pressure is feasible in lab scale but have been failing so far in the scale-up due to, in the frozen state, low glass transition temperature (Tg’). Vacuum freeze drying seems to be the gold standard. While tray freeze drying requires a lot of manual handling, which is especially difficult in the light of the recently published Annex 1 of the GMP guideline [4], dynamic freeze drying offers a contained processing with nearly no manual interference.required.

Keywords:

Spray freeze drying; Manufacturing Flexibility; Supply chain; Lyophilization; Freeze-drying

Lowering compaction pressure and sintering temperature of alumina using spray freeze granulation dried granules

Naoki Kondo1, Akihiro Shimamura, Mikinori Hotta, Junichi Tatami and Shinya Kawaguchi

Abstract

Spray drying (SD) and spray freeze granulation drying (SFGD) are the granulation processes of ceramic powder. Alumina green body made from SFGD granules via compaction has a relatively uniform structure without inter-granular pores, resulting in higher density and strength in the sintered body. This gives SFGD granules an advantage over SD granules. This study investigates the compaction pressure and sintering temperature of alumina granules produced by SD and SFGD. Using SFGD granules allows for the production of dense highstrength sintered alumina at lower compaction pressures and sintering temperatures. Even with higher compaction pressures applied to SD granules, the achieved sintered density falls short of that obtained with SFGD granules. These findings highlight the additional benefits of using SFGD granules over SD granules.

Keywords:

Spray drying, spray freeze granulation drying, alumina granule, Compaction pressure, Sintering temperature, Sintered density, Strength

Effect of spray freeze drying on the structural modification and rehydration characteristics of micellar casein powders

Jinbo Ren, Minjie Liao, Lingjun Ma, Fang Chen, Xiaojun Liao, Xiaosong Hu, Song Miao, John Fitzpatrick, Junfu Ji

Abstract

Micellar casein (MC) is usually spray-dried into powder form for transportation and storage. However, the micellar structure maintained by colloidal calcium phosphate (CCP) and hydrophobic forces leads to poor rehydration ability of MC powders, which limits its potential applications. Here, spray freeze drying (SFD) with controlled droplet size was used to produce MC powders. Their effects on the structure of MC and the subsequent rehydration characteristics including wetting, dispersion and dissolution were investigated. The results showed SFD powders obtained from smaller droplet size caused more than 50% of serum Ca2+ and PO43− to release from the micellar structure. These powder particles exhibited extremely high porosity (92%) and spherical morphology, which thus greatly shortened their wetting time. Furthermore, the smallest droplets during SFD were believed to produce the MC powders with the quickest dispersion and best solubility, as over 80% of the solids could be completely dissolved in just 15 min.

Keywords:

Spray freeze drying

Stable and inhalable powder formulation of mRNA-LNPs using pH-modified spray-freeze drying

Koki Ogawa, Otowa Aikawa, Tatsuaki Tagami, Takaaki Ito, Kohei Tahara, Shigeru Kawakami, Tetsuya Ozeki

Abstract

A powder formulation for mucosal administration of mRNA-encapsulated lipid nanoparticles (mRNA-LNPs) is expected to be useful for respiratory diseases. Although freeze-drying is widely used to obtain solid formulations of mRNA-LNPs, highly hydrosoluble cryoprotectants, such as sucrose are necessary. However, sucrose is not a suitable excipient for inhalation powders because of its hygroscopic and deliquescence properties. Spray freeze-drying (SFD) is a method to produce inhalable powder formulation. In this study, we prepared inhalable powder formulations of mRNA-LNPs without deliquescence excipients using pH-modified SFD, which strengthens the interaction between mRNA and ionizable lipids of LNPs by acidic pH modifier, leading to retention of the encapsulated structure of mRNA-LNPs even after SFD. Powdered mRNA-LNPs were suitable for inhalation, and mRNA was encapsulated in LNPs after SFD. The mRNA encapsulation efficiency and mRNA transfection efficiency of pH-modified SFD-mediated powdered mRNA-LNPs were higher than those of conventional SFD, although they were significantly lower than those of liquid intact mRNA-LNPs. However, after long-term storage, the powdered formulation of the mRNA-LNPs exhibited higher mRNA transfection efficiency than liquid mRNA-LNP. Powdered mRNA-LNPs also exerted their function in air–liquid interface cultivation and in vivo intratracheal administration. Collectively, the powder formulation of mRNA-LNPs especially prepared by SFD is expected to be applied for dry powder inhalers.

Keywords:

Spray freeze drying