Green propellants and the future of metered dose inhalers

The transition to next-generation propellants (NGPs) with low global warming potential (GWP) is redefining what success looks like for pressurized metered dose inhalers (MDIs). As sustainability targets tighten, developers must rethink how inhaled therapies are formulated, tested and manufactured without compromising performance.

Reformulating with NGPs affects not only the drug product but also its interaction with device materials and components, alongside stability and aerosol performance. Each change must be carefully understood to ensure consistent delivery and regulatory approval, making early strategy critical for low-GWP inhaler development and future metered dose inhaler manufacturing.

Aligning formulation, device and manufacturing strategy

In an article in The Medicine Maker, Andy Burns, Vice President of MDI Business Development at Kindeva, explores several of the key challenges and considerations shaping MDI development with next-generation propellants, including:

• Reformulation strategies that maintain stability and performance with new propellants
• Device component redesigns that ensure compatibility with different physicochemical properties
• Robust analytical data to support equivalence in aerosol performance and dose delivery
• Manufacturing processes that can be scaled to handle new propellant systems reliably

Formulation science, device engineering and manufacturing strategy must be closely aligned from the outset to avoid delays and rework. Early integration supports a clearer understanding of how each variable influences overall performance.

To gain a better understanding of the impact NGPs are having on MDI development, read the full article in The Medicine Maker: https://themedicinemaker.com/issues/2025/articles/october/green-propellants-and-the-future-of-metered-dose-inhalers/