Commercial-Scale Aqueous Spray Drying
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What Commercial Spray Drying Capacity Does Codis Offer?
Codis supports commercial aqueous spray drying across two high-volume manufacturing centers. At Haverhill, three GEA Niro tall form dryer scales support development, technical transfer, and commercial production. At Seymour, commercial aqueous spray drying capacity exceeds 5,000 metric tons annually, primarily for mineral-based products.
Aqueous Spray Drying Core Capabilities
Haverhill, UK Facility
Aqueous spray dryers at Codis’ Haverhill, UK facility are ideally suited for the development and production of large-volume products, including drug substance isolation, specialty excipients, and co-processed drug product intermediates to improve flow, compressibility, taste masking, and/or enhance mouthfeel. Our aqueous production-scale units can each process solutions, suspensions, and emulsion feed stocks, and all are fitted with Fike explosion suppression systems to enable the manufacturing of organic materials of St-1 or lower. Additionally, each of our production-scale aqueous units is integrated with upstream reactors, including LIST KneaderReactors for high-viscosity feedstocks.
Featured Haverhill Spray Dryers
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GEA Niro® TFD25 spray dryer
Codis’ GEA Niro TFD25 spray dryer is capable of three modes of operation: single-pass nitrogen, closed-cycle nitrogen, and conditioned air. Feed vessels support batches of up to 4,000L, with annual capacities in the tens of tons, making them suitable for batches in the hundreds of kilograms.
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GEA Niro® TFD250 spray dryer
The TFD25 also serves as a 1/10th pilot-scale unit for process development and technical transfer onto our GEA Niro® TFD250 spray dryer. The TFD250 operates with single-pass conditioned air with indirect heating, high-pressure nozzle atomization. This dryer is also uniquely modified with dry heat sanitization to produce low bioburden products, such as cyclodextrins.
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GEA Niro® TFD400 spray dryer
Our GEA Niro® TFD400 spray dryer operates with single-pass conditioned air with indirect heating. This system has both high-pressure and twin-fluid nozzle atomization systems, and can be optionally integrated with continuous flow reactors upstream of the dryer. Both the TFD250 and TFD400 platforms are capable of batch sizes in excess of 1000 kg, with annual plant capacities exceeding 1000 tons.
Approach to Tech Transfer
From gram-scale feasibility batches to sustained, multi-ton production runs on one of the world’s largest pharmaceutical spray dryers, Codis UK delivers capacity without compromise. Our commercial-scale infrastructure, harmonized process controls, and expert tech transfer teams ensure every process performs predictably as it moves from R&D to clinical supply to high-throughput commercial campaigns—whether you need a single engineering lot or ongoing global supply.
Analytical Expertise & Quality Control
Codis integrates comprehensive analytical testing with in-process monitoring to verify critical quality attributes at every step. Our Process Analytical Technology (PAT) tools enable real-time monitoring, supporting our spray drying facilities in Haverhill, UK, and Seymour, IN, USA, which operate under GMP-compliant systems to meet global quality standards.
Explore popular questions and topics on our commercial spray drying services
Scale and capacity to support scale-up and commercial spray drying needs
Codis uses a scale-aligned equipment strategy supported by harmonized process controls and technology transfer teams. The TFD25 serves as a one-tenth pilot-scale unit for development and transfer to the TFD250, while the broader Haverhill infrastructure supports progression from gram-scale feasibility work to sustained multi-ton campaigns. Analytical testing and in-process monitoring help verify critical quality attributes as the process moves across scales.
Frequently Asked Questions About Commercial Spray Drying
Explore popular questions and topics on our commercial spray drying services
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Codis can process solutions, suspensions, and emulsion feedstocks. Applications include drug substance isolation, specialty excipients, co-processed intermediates, and other engineered powders or functional products.
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Yes, the Haverhill production-scale (TFD250 and TFD400) aqueous units are fitted with extensive Fike explosion detection and suppression systems to support organic material processing. In addition, the Haverhill pilot scale TFD25 unit is equipped with a closed loop nitrogen insertion system to enable even broader processing tolerability to organic and combustible materials during development, enabling a robust safety case and data set to be generated to move to the larger units.
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Yes, Codis production-scale units are integrated with upstream chemical reactors, filtration and centrifugation systems, and purification apparatus to support feedstock chemical synthesis and purification prior to spray drying. Further, the TFD400 is integrated with continuous-flow reactors. All three aqueous dryers feature LIST KneaderReactors for high-viscosity feedstocks.
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Yes, the TFD-250 is fitted with a heat sanitization system that in combination with feed solution filtration can produce low bioburden products at the multi-10s of tons scale.
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Codis combines analytical testing with in-process monitoring and PAT to verify critical quality attributes and support GMP-compliant production for global markets. Codis has a long-standing history of PAT, having utilized on-line reaction analytics and real-time assay techniques for over 20 years in support of the large scale commercial activities, yielding unparallelled consistency and quality of product.
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.
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