Epsilon was appointed to deliver the introduction of pharmaceutical spray drying into an existing oral solid dose (OSD) facility. Recognised as one of the most technically demanding pharmaceutical unit operations, spray drying requires specialist process expertise to achieve reliable scale-up, high product recovery and GMP compliance, and to support upstream and downstream processes.
Using advanced process modelling and pharmaceutical engineering experience, Epsilon identified critical capacity pinch points, challenged the original equipment sizing and optimised the process design before procurement. This early intervention reduced project risk and ensured the facility was designed around the complete manufacturing process, not simply the installation of a spray dryer.
From FEED through detailed design to installation and commissioning, Epsilon delivered a fully integrated solution covering solvent handling, ATEX compliance, containment, utilities and recovery systems. Our extensive knowledge enabled us to design and supply a twin-vessel feed preparation system with N₂ as the basis of safety.
The result was a robust, future-ready manufacturing platform enabling the CDMO to introduce a high-value technology capability with improved efficiency, reduced risk and confidence in long-term operation.
For more details, see our full spray drying case study.