Spray Drying
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Haverhill’s Legacy of Spray Drying Excellence
The Haverhill, UK site is fully licensed for Investigational Medicinal Products (IMP) and also holds a commercial Manufacturer’s/Importer’s Authorization (MIA) issued by the MHRA. Additionally, the site is certified to ISO 14001 and ISO 50001 standards.
Given its diverse commercial product mix and the broad range of markets served globally, the Haverhill site has a long history of interaction with various regulatory agencies. Since 2015, it has successfully passed eleven audits conducted by local and foreign regulatory bodies, with zero critical observations. Currently, with our local regulatory authority, the MHRA, we are classified in their lowest risk tier due to our consistently high inspection performance and the absence of critical observations recorded over the past decade.
In addition to a strong emphasis on quality, the Haverhill site has a proven track record of environmental performance, with significant achievements in carbon reduction, recycling, and reducing process mass intensity.
Aqueous & Solvent-Based Spray Drying
Codis has three cGMP spray drying centers: two for products manufactured from aqueous feedstocks of organic or mineral-based product compositions, and one for products processed from solvent-based product feedstocks.
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Aqueous-Based Spray Drying
Learn more about Aqueous-Based Spray DryingThe Haverhill, UK, aqueous spray drying center features three large-scale GEA tall form dryers (TFD), ranging in size from TFD25 (100 kg water/hr evaporative capacity) to TFD400 (1,500 kg water/hr evaporative capacity). Our Seymour, IN, USA facility conducts, primarily for mineral-based products, aqueous-based spray drying at commercial scale and is capable of producing over 5,000 metric tons of material annually.
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Solvent-Based Spray Drying & ASDs
Learn more about Solvent-Based Spray Drying & ASDsCodis enhances the oral bioavailability of DCS Class 2a, 2b, and 4 compounds through spray drying of amorphous solid dispersions under cGMP conditions utilizing a Procept SD1 or GEA PSD-2. Our closed-loop solvent spray dryers operate under inert nitrogen with twin-fluid and high-pressure atomization. Compatible with volatile solvents—including acetone, methanol, ethanol, and dichloromethane—our systems deliver optimized ASD performance and stability.
What Pharmaceutical Spray Drying Services Does Codis Provide?
Codis supports both aqueous and solvent-based pharmaceutical spray drying.
Aqueous spray drying at Codis are truly unique with the combination of continuous and semi-continuous chemical reactors coupled to each of the three aqueous spray driers. These reactors are capable of a wide range of processing solvents and chemistries and allows for highly efficient reactants-to-dry-product manufacture. Our capabilities extend from development through to high-volume commercial production for API’s, Excipients, Intermediates and particle engineered Functional Products, including evaporative capacities up to 1,500 kg of water per hour at Haverhill and annual production of more than 5,000 metric tons at Seymour.
Solvent-based capabilities support amorphous solid dispersions for DCS Class 2a, 2b, and 4 compounds using nitrogen inerted closed-loop operating systems with batch scales from milligram quantities to hundreds of kg.
How to Choose a Spray Drying CDMO
Matching the right partner and process to the right program
The right spray drying CDMO should be selected against the needs of the molecule, process, development phase, and intended commercial supply strategy. Key evaluation criteria include:
- Scale continuity from material-sparing high-efficiency formulation and process development through clinical and commercial manufacture
- Versatility across aqueous and solvent systems, including closed-loop solvent processing capabilities
- Equipment and atomization options suited to the target particle properties
- Process modeling, PAT, analytical, and quality-control support
- A structured technology transfer approach that carries product and process knowledge forward
- A regulatory and inspection history appropriate for the target markets
- Oral solid dose formulation development and clinical supply
Codis combines this lifecycle coverage with cGMP spray drying centers in the US and UK, onsite development teams, and commercial capacity ranging from gram-scale feasibility work to multi-ton supply.
The Right Scale for Every Phase & Every Program
From product for feasibility studies to multi-ton commercial runs, Codis offers a seamless continuum of capacity.
Data Science & Modeling
Our Modeling Toolbox Includes
Mechanistic models
Statistical & machine learning models
Process Analytical Technology (PAT) informed inline sensing & multivariate control
Technology Transfer
We transfer in processes from innovator organizations or other CDMOs, then scale them using a risk-based, QbD approach. We incorporate all previously generated product and process knowledge, addressing gaps as necessary. Using this as a base, we scale from Process Design through Process Performance Qualification (PPQ) and Continued Process Verification (CPV). Ultimately, our customers achieve reliable, inspection-ready supply faster without risking product supply.
Our Technology Transfer Protocols Include
Risk assessment
Technology gap analysis
Process and analytical method transfer
Stability assessment
Quality control and release testing
Validation
Regulatory submission support
Frequently Asked Questions About Pharmaceutical Spray Drying
Explore popular questions and topics on our spray drying services
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Pharmaceutical spray drying converts a liquid feed, such as a solution, suspension, or emulsion, into a dry engineered powder.
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Yes. Codis operates aqueous spray drying centers for development and commercial production and solvent-capable spray dryers that run in closed-loop mode under inert nitrogen for products such as amorphous solid dispersions, also for development and commercial production.
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Yes. Codis has decades of experience developing and characterizing enabling formulations for pre-clinical studies.
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Yes. Codis supports feasibility, process design, technology transfer, PPQ, continued process verification, and commercial supply across multiple spray dryer scales and system types.
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Codis provides spray drying capabilities at Nottingham and Haverhill in the UK and at Seymour, Indiana in the US with specialized capabilities and processing focus adapted by site.
Discover Codis
Explore how Codis applies its expertise in spray drying, microencapsulation, continuous granulation, final dosage forms, and functional products to meet your formulation and manufacturing needs.
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Commercial Spray Drying
Full lifecycle, development, and production expertise for high-volume commercial aqueous spray drying.
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Codis Amorphous Solid Dispersion (ASD)
Industry-leading know-how to design, scale, and manufacture amorphous solid dispersions for improved bioavailability of poorly soluble compounds.
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Microencapsulation
Proprietary microencapsulation processes to improve taste, odor masking, stability, or release profile.
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Continuous Granulation
Continuous high-shear granulation to improve flow, compressibility and disintegration.
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Organic & Polymer Chemistry
Advanced organic synthesis and polymer engineering, enabling robust, scalable manufacturing.
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Analytical Services
State-of-the-art instrumentation combined with data-science–driven PAT to provide method development, validation, release, and stability testing services.
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Final Dosage Forms
Leading global experts in direct compression and two-piece encapsulation products for vitamin, mineral and supplement markets.
Codis Insights & Updates
Stay current with the latest in particle engineering science and Codis articles and resources.
Connect with us to explore how our particle engineering, commercial spray drying, formulation, and advanced manufacturing capabilities deliver high-quality, dependable supply for even the most challenging products.