Spray-drying of polymer solutions across a broad concentration range and the subsequent formation of a few micro- ∼nano-meter sized fibers

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Spray drying is a widely utilized technique for the concentration and fine particulation of dried products. This study demonstrated that a versatile spray dryer, equipped with a two-fluid nozzle atomizer, can convert polymer solutions into nanoscale fibers by manipulating the conditions of the polymer solutions. The polymers employed in this research included polyvinylpyrrolidones (Mw 24.5 k to 60 kDa), dextrans (70 k to 450–650 kDa), pullulan, gum Arabic, Eudragit and agar, with methanol and water serving as solvents. Various combinations of polymers and solvents were subjected to spray drying at polymer concentrations ranging from 5 to 1000 g/L. Scanning electron microscopy analyses of the spray-dried samples indicated that the products transitioned from micrometer-sized particles to sub-micrometer fibers in several instances when the polymer concentrations exceeded specific threshold levels. The investigation also explored the relationship between these threshold concentrations and the surface tension and viscosity of the polymer solutions.