Spray drying is a well-established process for generating particles for various applications, including pharmaceuticals. In this process, atomization plays a crucial role by defining the size of the droplets and, consequently, particle size. While ultrasound is commonly used to enhance atomization by reducing droplet size, a novel approach has been introduced that utilizes plug flow to generate plugs resonating with an applied ultrasound frequency, triggering surface atomization. This study investigates the applicability of this method for microfluidic atomization and spray drying, particular for pharmaceutical carrier particles. The generated droplets exhibit a size of 7.24 μm and a PDI of 0.18, indicating a monodisperse distribution. The droplets are produced in discrete burst events, enabling an energy-efficient pulsed process with an applied power of less than 1 W. This approach successfully generates lipid nanoparticles with an average size of 140 nm, underscoring its potential for nanoparticle production.
