• Mannitol carrier and drug-mannitol composites were produced using LTSAA. • Fine corrugated surface of mannitol-leucine particles enhanced aerosol performance. • Aerosol performance of composite enhanced 3.4 times compared to as-received drug. • Drug release of composite was 15.6 times faster than that of as-received drug. • Drug-mannitol composites acted as instant formulation of inhalable dry powder. Mannitol carrier and drug-carrier composite particles were produced via low-temperature supercritical assisted atomization (LTSAA). The enhanced aerosolization of the mannitol carrier particles with added L -leucine could be attributed to the formation of fine corrugated particles, which reduced the interparticle cohesion and led to better flowability of the mannitol carrier particles. A poorly water-soluble drug, beclomethasone dipropionate (BDP), and mannitol co-precipitated during LTSAA with the optimal addition of 9.1 mass % L -leucine. The in vitro aerosolization and dissolution experiments indicated that the fine particles fraction ( FPF ) of the drug-carrier composite particles was 3.4 times ( FPF = 49.9 %) higher than that of the as-received BDP ( FPF = 14.7 %) and the 63.2 % drug release time of the drug-carrier composite particles was 15.6 times faster than that of as-received BDP. This study suggests that the drug-carrier composites produced using LTSAA can be employed in the instant formulation of inhalable dry powder.
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