Thomas Daly
Development engineer
In May 2026, Bespak presented expert insights on the newest science for inhaled drug delivery at RDD. Development Engineer at Bespak®, Thomas Daly, presented new research offering insight into how pressurised Metered Dose Inhalers (pMDIs) refill between doses — a process that plays a critical role in ensuring consistent and reliable drug delivery for patients.
As the inhalation industry transitions to next-generation propellants for low carbon pMDIs, understanding how formulation changes affect device performance and dose consistency is becoming increasingly important.
Using high-speed X-ray imaging, the study captured real-time fluid flow inside a functioning pMDI valve at a level of detail not previously possible. By combining this imaging technology with custom-designed housing, the team developed a novel approach for visualising and quantifying the refill process.
The research showed that refill performance can vary significantly depending on the propellant, formulation composition and valve geometry. Additives such as ethanol and active pharmaceutical ingredients (APIs) impacted both refill speed and fill levels, while valve design could be modified to better match the needs of specific formulations.
For developers working on low carbon pMDIs, this type of insight is increasingly valuable. Understanding the interaction between formulation and device design early in development is essential to maintaining dose consistency for patients during the transition to next-generation propellants.
More broadly, the research demonstrates Bespak's ability to combine advanced analytical science with practical device engineering to solve complex inhalation challenges. By applying cutting-edge imaging techniques to real-world pMDI systems, Bespak continues to strengthen its position as the specialist inhalation contract development and manufacturing organisation (CDMO), helping partners accelerate innovation and reduce development risk for future inhaled therapies.
Contact us today to accelerate your transition to next-generation propellants.
