Tuning the Shape of Spray-Dried Pullulan Particles Through Feed Rheological Behavior

Pullulan is a natural polysaccharide used in many health products, including dry powders for oral and pulmonary administration. In these cases, the control of the shape and dimensions of particles is crucial for obtaining the desired functionality. Different from other polysaccharides, pullulan cannot be easily shaped without chemical modifications or adjuvants’ addition. This work aims to systematically investigate the impact of the solvent composition and polymer concentration on the possibility of tuning the pullulan particle shape by spray drying. The results revealed that the microparticle-to-fiber transition can be induced using a hydro-alcoholic solution since ethanol increased the relaxation time and reduced the evaporation rate. Furthermore, a high Péclet number during drying favors the formation of wrinkled surfaces at all feed compositions. Overall, these data evidenced the possibility of tuning the spray-dried product morphology without any processing aids, paving the way for new applications of pullulan, especially in the pharmaceutical field.