Pulmonary Dosage Forms Development & Manufacturing

Upperton is a leading contract development and manufacturing organisation (CDMO) specialising in delivering pulmonary and inhalable dosage forms

Inhalation

Advancing Inhaled Drug Delivery

For nearly 30 years, Upperton has been supporting the development and manufacture of pulmonary dosage forms, helping pharmaceutical and biotechnology companies bring innovative inhaled therapies to patients. Our expertise spans both Dry Powder Inhalers (DPIs) and Soft Mist Inhalers (SMIs), enabling us to select and develop the optimal pulmonary delivery strategy based on your molecule, therapeutic target and patient population.

The respiratory system provides an attractive route for the delivery of both small molecules and biotherapeutics, offering opportunities for local treatment of respiratory disease as well as systemic drug delivery. Through our integrated development services, we support formulation design, device selection, performance testing, scale-up and GMP manufacturing for inhaled products

Our model is built around:

  • One-site delivery for seamless project execution
  • Embedded senior leadership on every project
  • Scalable science that evolves with your programme
  • Flexible, responsive partnerships tailored to biotech needs

When you are ready to begin your CDMO journey, Upperton specialises in:

Inhalation drug products (pulmonary delivery)
Oral solid dosage form tablets and capsules
Oral solid dosage forms (OSD)
Nasal drug delivery systems
Parenteral formulations

Our Pulmonary Dosage Form Capabilities

Our pulmonary development expertise spans formulation, processing, testing and device optimisation, supporting programmes from early development through to GMP manufacturing.

Dry Powder Inhaler (DPI) formulation development

Soft Mist Inhaler (SMI) formulation development

Spray drying

Micronisation

Rapid formulation screening

Clinically relevant performance testing

Device compatibility assessments

GMP manufacturing

Device support and optimisation

Selecting the right Pulmonary Delivery Form

Choosing between a DPI and an SMI depends on several factors. For example, SMIs may be better suited to patients with limited inspiratory capability, while DPIs can offer advantages for biologics, vaccines and sustainability-driven development programmes. Our experts work closely with clients to evaluate these factors and identify the most appropriate pulmonary drug delivery solution.

Dry Powder Inhalers (DPIs)

Dry powder inhalers continue to play an increasingly important role in the delivery of next-generation inhaled therapeutics. As inhaled biologics, vaccines and complex molecules gain momentum, DPIs offer distinct advantages in formulation flexibility, stability and sustainability.

Why Choose a DPI?

Sustainable Inhaled Drug Delivery

Many traditional pressurised metered-dose inhalers (pMDIs) utilise hydrofluorocarbon propellants with a high global warming potential. DPIs eliminate the need for propellants, making them an increasingly attractive and sustainable alternative.

Biologics Compatibility

The growing interest in biologics has increased demand for pulmonary delivery approaches that help preserve molecular structure and stability. Dry powder formulations can offer significant advantages for sensitive biologic products when compared with liquid-based delivery systems.

Deep Lung Delivery

Many advanced therapeutics require deposition within the deep regions of the lung for optimal efficacy. Carefully engineered DPI formulations can support efficient delivery to these target areas.

Soft Mist Inhalers (SMIs)

Soft Mist Inhalers generate a slow-moving, fine aerosol cloud that delivers medication directly to the lungs with minimal patient inhalation effort. Unlike traditional inhalers, SMIs do not rely on propellants or high inspiratory flow rates to generate the aerosol.

This makes SMIs particularly well suited to specific patient populations, including children and elderly patients who may struggle with the inspiratory effort required for other inhalation devices.

Why Choose an SMI?

Enhanced Lung Deposition

SMIs can achieve lower deposition in the throat while increasing delivery to deeper regions of the lung, helping maximise therapeutic effectiveness.

Reduced Patient Dependence

Because aerosol generation is largely independent of the patient's inhalation effort, SMIs can offer more consistent drug delivery across diverse patient groups.

Support for Complex Therapies

SMIs are increasingly utilised in applications where consistent lung deposition is critical, including asthma, COPD and fixed-dose combination products

partnership

Why Partner with Upperton

We provide fully integrated services across every stage of drug product development:

One Site

Integrated, end-to-end capabilities delivered under one roof.

One Team

The same team from your early-stage development through to preparation for commercial launch.

Scanning electron microscope (SEM) photograph showing a powder made up of solid amorphous spray dried dispersions (SDDs) of the optimum size for inhaled formulations (1 to 5 micrometres)

Complex Molecule Expertise:

Proven track record in solving formulation and delivery challenges.

Executive Leadership on Every Project:

Direct access to experienced senior leadership for strategic oversight and decision-making.

Learn more about inhalation drug delivery

With over 25 years experience in inhaled drug delivery, Upperton are experts in delivering via nasal and pulmonary pathways.

Inhalation Development and Manufacturing Fact Sheet Delivering Complex Molecules via Inhalation

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Inhalation Delivery FAQs

The choice between a soft mist inhaler vs a dry powder inhaler largely depends on the drug being delivered. However, target patient is also a strong determining factor in device selection. For example, SMIs are usually better for children or the elderly who cannot breathe in as strongly, as SMIs require far less patient effort than DPIs. 

A Soft Mist Inhaler (SMI) is an inhalation device designed to deliver medication to the lungs as a slow‑moving, fine aerosol mist. Unlike traditional inhalers, SMIs do not rely on propellants or the patient’s inspiratory effort to generate the aerosol. 

Asthma COPD Long acting bronchodilators (LABA, LAMA) Fixed-dose combinations where consistent lung deposition is critical 

More complex device engineering Higher unit cost than basic pMDIs Priming and handling steps can be more involved Fewer off‑the‑shelf platform options compared with pMDIs or DPIs 

The next steps involve selecting the target product profile, characterising the API, determining the feasibility of the drug, and then establishing device compatibility. 

Some of the common challenges involve moisture sensitivity, the stability of biologics, and the flowability of powders. Each of these challenges can be resolved through careful formulation development. Our executive leadership team are extremely experienced in dry powder formulation development, and will be able to advise you on the best course of action for your project. 

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We provide fully integrated services across every stage of drug product development.

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