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Methods and apparatus are provided for making particles comprising: (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material (e.g., a pharmaceutical agent), through an atomizer and into a primary drying chamber, having a drying gas flowing therethrough, to for

Methods and apparatus are provided for making particles comprising: (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material (e.g., a pharmaceutical agent), through an atomizer and into a primary drying chamber, having a drying gas flowing therethrough, to form droplets comprising the solvent and bulk material dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in drying gas; and (c) flowing the particles and at least a portion of the drying gas through a jet mill to deagglomerate or grind the particles. By coupling spray drying with “in-line” jet milling, a single step process is created from two separate unit operations, and an additional collection step is advantageously eliminated. The one-step, in-line process has further advantages in time and cost of processing.

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1. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form

1. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill. 2. The method of claim 1, wherein, before step (c), the feedstream of step (b) is directed through a particle concentration means to separate and remove at least a portion of the drying gas from the feedstream.3. The method of claim 2, wherein the particle concentration means comprises a cyclone separator.4. The method of claim 2, wherein the particle concentration means comprises one or more devices selected from the group consisting of gravity settling chambers, electrostatic charge precipitators, impingement separators, mechanical centrfugal separators, and uniflow cyclones.5. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; (c) flowing the feedstream through a particle concentration means to separate and remove between about 50 and 100 vol. % of the drying gas from the feedstream; and then (d) flowing the feedstream through a jet mill to deagglomerate or grind the particles. 6. A method for making particles comprising:(a) sprayer an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; (c) flowing the feedstream through at least one secondary drying chamber in fluid communication with the discharge outlet of the primary drying chamber to evaporate a second portion of the solvent into the drying gas; and then (d) flowing the feedstream through a jet mill to deagglomerate or grind the particles. 7. The method of claim 6, wherein the at least one secondary drying chamber comprises tubing having an inlet in fluid communication with the discharge outlet of the primary drying chamber, wherein the ratio of the cross-sectional area of the primary drying chamber to the cross-sectional area of the tubing is at least 4:3, and wherein the ratio of the length of the tubing to the length of the primary drying chamber is at least 2:1.8. The method of claim 1, wherein step (c) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.9. The method of claim 1, wherein step (c) is conducted to grind the particles.10. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the bulk material comprises a pharmaceutical agent. 11. The method of claim 10, wherein the bulk material further comprises a shell material.12. The method of claim 11, wherein the shell material is selected from the group consisting of polymers, lipids, sugars, carbohydrates, proteins, peptides, amino acids, and combinations thereof.13. The method of claim 11, wherein the shell material comprises a biocompatible polymer.14. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the particles are microparticles. 15. The method of claim 14, wherein the microparticles comprise microspheres having voids or pores therein.16. The method of claim 10, wherein the bulk material comprises a therapeutic or prophylactic agent.17. The method of claim 16, wherein the therapeutic or prophylactic agent is hydrophobic and the particles comprise microspheres having voids or pores therein.18. The method of claim 10, wherein the bulk material comprises a diagnostic agent.19. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the method further comprises adding to the feedstream an excipient material, a pharmaceutical agent, or both. 20. The method of claim 19, wherein the excipient material, the pharmaceutical agent, or both, is/are added before or after the feedstream has flowed through a particle concentration means to separate and remove at least a portion of the drying gas from the feedstream.21. The method of claim 19, wherein the excipient material, the pharmaceutical agent, or both, is/are in the form of a dry powder.22. The method of claim 19, wherein the excipient material is selected from the group consisting of amino acids, proteins, carbohydrates, polymers, starches, surfactants, and combinations thereof.23. A method for making particles comprising:(a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas; (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream; and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles; wherein the method further comprises spraying a second emulsion, solution, or suspension through at least one additional atomizer and into the primary drying chamber. 24. The method of claim 23, wherein the composition of the second emulsion, solution, or suspension is different from the composition of the first emulsion, solution, or suspension.25. The method of claim 24, wherein the bulk material comprises a first pharmaceutical agent and the second emulsion, solution, or suspension comprises a second pharmaceutical agent, an excipient material, or a combination thereof.26. The method of claim 5, wherein the bulk material comprises a pharmaceutical agent.27. The method of claim 6, wherein step (d) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.28. The method of claim 6, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.29. The method of claim 6, wherein the particles are microparticles.30. The method of claim 6, wherein the bulk material comprises a pharmaceutical agent.31. The method of claim 10, wherein step (c) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.32. The method of claim 10, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.33. The method of claim 10, wherein the particles are microparticles.34. The method of claim 14, wherein step (c) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.35. The method of claim 14, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.36. The method of claim 14, wherein the bulk material comprises a pharmaceutical agent.37. The method of claim 19, wherein step (c) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.38. The method of claim 19, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.39. The method of claim 19, wherein the particles are microparticles.40. The method of claim 23, wherein step (c) is conducted to deagglomerate at least a portion on of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.41. The method of claim 23, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.42. The method of claim 23, wherein the particles are microparticles.43. A pharmaceutical composition comprising particles made the method of claim 10.44. A pharmaceutical composition comprising particles made by the method of claim 1.45. A pharmaceutical composition comprising particles made the method of claim 14.46. The method of claim 1, wherein step (c) reduces the residual solvent or moisture content of the particles from step (b).47. The method of claim 19, wherein the bulk material of step (a) comprises a first pharmaceutical agent, and a second pharmaceutical agent is added to the feedstream of step (b).48. The method of claim 1, wherein the particles are microparticles.49. The method of claim 1, wherein the bulk material comprises a pharmaceutical agent.50. The method of claim 1, wherein the bulk material comprises a therapeutic or prophylactic agent and the particles are microparticles.51. The method of claim 5, wherein step (d) is conducted to deagglomerate at least a portion of agglomerated particles, if any, while substantially maintaining the size and morphology of the individual particles.52. The method of claim 5, wherein the jet mill comprises a spiral jet mill or other fluid energy impact mill.53. The method of claim 5, wherein the particles are microparticles.