Herein, we report the laboratory-scale continuous synthesis of amorphous solid dispersions (ASDs) using a thin film evaporator (TFE). Case studies performed on formulations comprising thermosensitive and/or shear-sensitive drug substance with several combinations of polymer, surfactant, and glidant, are presented. The thermal degradation, residual crystallinity, loss on drying, and powder flow properties of the ASD intermediates are reported and compared with ASD intermediates obtained from existing technologies such as hot melt extrusion, spray drying, and vacuum drum drying. Furthermore, highly viscous formulations are evaluated using the TFE and compared against existing technologies. Model equations for the scale-up of TFE are presented, thereby identifying the key operating parameters and scaling factors. Additionally, considerations for handling potent formulations are discussed and appropriate equipment design modifications are proposed. This study provides insights into the applicability of TFEs for continuous solvent-based ASD synthesis, defining the scalability, scope, and limitations of this technology.
