About the project
This project will investigate how ultrasound can produce more uniform, stable and high-quality granular pharmaceutical powders while reducing energy use. Combining experimental research, advanced particle characterisation and process modelling, the work will enable more efficient, scalable drug manufacturing.
The pharmaceutical industry increasingly requires manufacturing technologies that can deliver powders with tightly controlled particle size, morphology, flowability and dissolution performance, while maintaining product stability and reducing energy consumption. Conventional spray drying, particularly using two-fluid nozzles, can provide limited control over droplet size and particle characteristics and may expose heat-sensitive pharmaceutical materials to undesirable thermal and shear stresses.
This project will develop an innovative spray drying system incorporating ultrasonic atomisation to produce granular pharmaceutical powders with improved and more consistent properties. Ultrasonic atomisation uses high-frequency sound waves to generate fine droplets with controlled size, offering a promising route to improved atomisation efficiency, reduced shear and lower energy consumption. The research will establish the relationships between key processing parameters, including ultrasonic frequency, feed concentration, drying temperature and airflow rate, and the resulting particle characteristics, including size, morphology, density, flowability, compressibility and dissolution behaviour.
The project will combine experimental investigation, process optimisation and modelling to develop a validated understanding of the mechanisms governing ultrasonic atomisation and spray drying. Advanced characterisation techniques, including scanning electron microscopy (SEM) and laser diffraction, will be used to evaluate particle properties and support process–structure–performance relationships.
Expected outcomes include an optimised and scalable ultrasonic spray drying process, a validated process model, mechanistic understanding of ultrasound-assisted atomisation and prototype granular pharmaceutical formulations. The research will provide valuable training in pharmaceutical processing, particle engineering, experimental design, advanced characterisation and process modelling, while addressing an important industrial challenge in the manufacture of high-quality pharmaceutical powders and drug delivery systems.
The School of Chemistry and Chemical Engineering is committed to promoting equality, diversity inclusivity as demonstrated by our Athena SWAN award. We welcome all applicants regardless of their gender, ethnicity, disability, sexual orientation or age, and will give full consideration to applicants seeking flexible working patterns and those who have taken a career break. The University has a generous maternity policy, onsite childcare facilities, and offers a range of benefits to help ensure employees’ well-being and work-life balance. The University of Southampton is committed to sustainability and has been awarded the Platinum EcoAward.
