Formation of delta-mannitol by co-spray drying: enhancing the tabletability of paracetamol/mannitol formulations

δ-mannitol is a metastable polymorph of mannitol, known for its superior tableting properties. However, there no easy, reproducible and scalable production method δ-mannitol. It was evaluated whether could be formed via co-spray drying with an API exhibiting tabletability issues, to improve the in one-step process prior compaction. Aqueous suspensions paracetamol β-mannitol were dried. Raman spectroscopy used identify mannitol polymorphs. In these formulations, key factor allow formation since traces δ-polymorph detected after spray pure feed. The presence confirmed even low paracetamol/mannitol ratios (1:99). content varied depending on parameters, predominantly by airflow. A lower airflow promoted δ-mannitol, while more α-mannitol when applying higher starting material, β-mannitol, often longer detectable spectroscopy. dried powders clearly improved association concentration. co-processed showed comparison physical mixtures materials. Harder tablets maximal tensile strength 2.9 MPa at main compression pressure 247 achieved.