Samples of industrial and pilot plant spray-dried materials were obtained f
rom various manufacturers together with details of drying conditions and fe
ed specifications. The samples were subjected to qualitative and semi-quant
itative examination to identify structural and morphological features. The
results were interpreted in terms of bulk physical properties and related t
o drying conditions. Three distinct categories of particle morphology were
identified, namely, crystalline, skin-forming and agglomerate. Selected pro
perties such as powder flowability, particle and bulk density, particle siz
e and particle friability were shown to have a direct relationship to morph
ological structure.