Download our fact sheet to discover the key benefits of the Pulmospray™ Soft Mist Inhaler.

The post Resyca® Pulmospray™ Soft Mist Inhaler (SMI): fast preparation and breath-synchronised delivery first appeared on Resyca.

Publication: ONdrug Delivery 180, 26th November 2025

Abstract: With the increasing demand for new inhalation therapies, the need for efficient, patient-centric and sustainable delivery platforms is paramount. The Resyca PFSI is uniquely positioned to meet these needs, enabling precise and reliable delivery of even the most fragile molecules.

Soft Mist Inhaler (SMI) technology is transforming inhaled drug delivery — making treatments more efficient, patient-friendly, and sustainable.

Key highlights from the article:

• Enhanced Usability: SMIs reduce coordination errors and improve lung deposition, supporting better outcomes for diverse patient groups.
• Compatibility with Biologics: Ideal for next-generation therapies like vaccines and gene therapies, where gentle aerosolisation is crucial.
• Innovation with PFSI™: Resyca’s Pre-Filled Syringe Inhaler sets new standards for precision dosing, scalability, and patient-centric design. PFSI – Soft Mist Inhaler SMI.

This innovation is paving the way for tailored dosing, improved treatment adherence, and cost-effective delivery—critical for biologics and high-value therapies.

The post Enhancing drug delivery with innovative soft mist inhaler technology first appeared on Resyca.

Journal: European Journal of Pharmaceutical Sciences, Volume 214, 2025

Abstract: Inhalable mRNA is an emerging field holding great potential for applications as mucosal vaccination, antiviral therapy or protein replacement therapies, but efficient delivery remains a bottleneck.

In this study, we explore the use of a Soft Mist Inhaler (SMI), based on Rayleigh-breakup, for pulmonary mRNA delivery. We found that the SMI successfully aerosolised GFP mRNA encapsulated in liposomes while maintaining colloidal stability, mRNA integrity and in vitro transfection efficiency in A549 cells. Furthermore, the device enabled simultaneous delivery of nucleic acids in various sizes using a model CRISPR/Cas13d system.

The formulation could be reproducibly aerosolised with a low geometric standard deviation (GSD) and optimal aerosol droplet size for lung delivery. Based on the aerosol data, lung deposition modeling was conducted, indicating high lung deposition with minimal exhaled fraction. In comparison, aerosolization by a conventional Vibrating Mesh Nebuliser led to significant loss of nanoparticles and transfection efficiency. Utilising SMIs may facilitate pulmonary delivery of mRNA nanoparticle formulations by lowering stability-associated hurdles while providing intrinsically high deposition in the lungs.

Reference

The post Soft mist inhaler nebulisation by Rayleigh-breakup largely preserves functional integrity of liposomal mRNA in respirable aerosols first appeared on Resyca.

Resyca is a joint venture between Bespak and Medspray. Bespak has a strong franchise and is an established supplier of inhalation devices to the pharma industry.

By having access to this proprietary device manufacturing line, Resyca can provide shorter time lines for new customers. The idea is that multiple customers will use the same device manufacturing platform with minor pre designed change options like the volume per actuation and the outer parts design, including colours and labeling. This way Resyca can achieve economies of scale for the soft mist inhaler platform, for multiple clients who separately would not have enough unit sales to justify the capital investments necessary.

The post Bespak – device manufacturing first appeared on Resyca.

Journal: Journal of Drug Delivery Science and Technology, Volume 115, Part 1, 2026

Abstract: Pulmonary delivery of mRNA-lipid nanoparticles (mRNA-LNPs) offers a promising non-invasive route of administration for pulmonary gene therapy, vaccine applications, amongst others.

However, aerosolisation can compromise nanoparticle stability, affecting its payload and thus delivery efficiency. This study evaluates the impact of aerosolisation via Rayleigh breakup and Savart impinging jet-based SMIs and various mesh nebulisers in preserving mRNA-LNP integrity and thus optimising pulmonary deposition.

The PFSI (Resyca) and Respimat (Boehringer Ingelheim) SMIs, as well as the Innospire Go and Pari eFlow mesh nebulisers were assessed for their impact on LNP particle size, zeta potential, encapsulation efficiency, and mRNA stability.

The PFSI SMI maintained mRNA-LNP physicochemical properties with minimal aggregation and superior encapsulation efficiency, while the other devices induced significant particle alterations and mRNA degradation.

These findings highlight the potential of SMIs, particularly the PFSI device, for inhaled mRNA-LNP delivery. Its ability to maintain nanoparticle stability warrants clinical evaluation.

Reference

The post Rayleigh-based soft mist inhalers preserve mRNA-LNP integrity for pulmonary delivery first appeared on Resyca.

Event: DDL 2024, 11 – 13 December 2024, Edinburgh, United Kingdom

Abstract: Resyca’s PFSI device maintains anti-microbial ingress valve and delivery performance post-storage at freezing conditions.

This finding further demonstrates the suitability of Resyca’s technology for the delivery of biological products such as proteins and RNA based formulations, where maintaining sterility without preservatives is important and which are frequently stored at sub 0 conditions.

The post Assessment of the novel soft mist Pre-filled Syringe Inhaler (PFSI) device performance after storage at sub 0 °C temperature conditions first appeared on Resyca.

Event: DDL 2023, 6 – 8 December 2023, Edinburgh, United Kingdom

Abstract: A device screening method is presented which takes aerosol parameters, deposition modelling, and post aerosolisation mRNA integrity data to predict lung deposition of functional mRNA as a percentage of fill dose. In the prediction performed here, the Aerogen Solo, Pari eFlow rapid, and the Resyca Pulmospray™ result in 12%, 2% and 51% lung deposition of functional mRNA, respectively.

The delivery of full-length mRNA is important, as only full-length mRNA results in the translation of the wanted biological active protein. When selecting a drug delivery device for the inhalation of sensitive biologics, such as mRNA formulations, the device specific drug delivery characteristics must be considered.

Based on nebuliser fill volume, large differences in active mRNA delivery efficiently may exist and careful selection of the device is recommended. Particularly for biological compounds that carry high costs, substantial cost savings may be realised when selecting an efficient delivery device. The Resyca Pulmospray™ device is such an efficient device that may provide up to 50% of the filled mRNA to the deep lung intact.

The post A device screening method for predicting delivery of inhaled mRNA via a nebuliser first appeared on Resyca.

Publication: Drug Development & Delivery, Volume 24(7), 2024

Abstract: Worldwide, rising cases of chronic lung conditions, such as asthma, cystic fibrosis, pulmonary arterial hypertension (PAH), and chronic obstructive pulmonary disease (COPD), are driving demand for inhalation drug delivery devices.

As respiratory diseases rise and biologics rapidly expand, the need for advanced, patient-friendly delivery solutions is accelerating. This article explores how Soft Mist Inhaler (SMI) technology is opening new pathways for inhaled and nasal biologics – from improving dosing performance to reducing reliance on needle-based administration.

By reading our article, you’ll discover:

• Why inhalation and nasal delivery are becoming strategic routes for biologics.
• How reformulation into inhaled or nasal formats can extend product life cycles.
• The key challenges of delivering sensitive biologics — and how soft mist technology overcomes them.
• The critical role of industry partnerships in accelerating device innovation and development efficiency.

Download the full article to find out more.

The post How soft mist inhalers support improved biopharma drug delivery first appeared on Resyca.

Publication: International Pharmaceutical Industry, Volume 16(1), 2024

Abstract: Biologics are reshaping modern healthcare, yet their full potential is often constrained by traditional administration routes. Recent advances in nasal inhalation, particularly soft mist nasal spray technologies, are redefining what is possible for sensitive biopharmaceutical formulations.

The rapid growth of both inhalation technologies and the global biologics market is creating new opportunities for patient-friendly, non-invasive drug delivery. Nasal inhalation and especially soft mist nasal spray technology, is emerging as a strong alternative to traditional parenteral routes, offering fast systemic uptake, improved patient experience, and expanded access beyond clinical settings.

However, biologics bring unique development challenges, including formulation sensitivity and the need for precise, consistent nasal deposition. Resyca’s next-generation soft mist nasal spray platforms address these barriers through biologic-compatible nozzle designs, controlled plume characteristics, and device architectures that minimise formulation stress while enhancing delivery efficiency.

As patent expiries accelerate competition in the biologics sector, nasal reformulation becomes a strategic path to lifecycle extension. Soft mist nasal sprays enable developers to differentiate existing products, streamline regulatory pathways, and unlock new therapeutic potential, positioning nasal delivery as a pivotal innovation for the next era of biopharmaceuticals.

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The post Transforming the biologics product lifecycle with inhalation innovation first appeared on Resyca.

Event: RDD 2024, 5-9th May 2024, Tucson, Arizona

Abstract: When selecting a suitable inhaler for effective drug delivery, it is crucial to consider both particle/droplet size and inspiratory flow rate achievable with a specific device.

Inspiratory flow rate varies significantly among inhalers due to different flow resistance. Novel SMIs, such as the pre- filled syringe SMI (PFSI®) offer a customisable range of flow resistances to suit specific patient populations.

Slow and deep inhalation is known to result in high lung deposition and determining the optimal device resistance is a critical design consideration. This study assesses inspiratory flow patterns and drug lung deposition of healthy volunteers and patients with pulmonary arterial hypertension (PAH) using SMIs with different flow resistance.

Conclusions of the Publication:

• Inhalers featuring different flow resistances
  influence the inhalation flow profile of patients.
• Measurements a lung deposition modelling
  indicate that inhalation at higher flow resistance leads to more consistent flow profiles and higher lung dose with lower patient to patient variability.
• All study subjects were able to perform appropriate inhalation manoeuvres at all flow resistances with AIT of 6–10 seconds, with AIF of 12.2–30.4 L/min and AIV of 1.3–2.9 L.
• Small differences in lung deposition are observed for different particle size distributions.
• Emphasizing good inhalation technique is crucial for effective treatment. Selecting an inhaler device such as the PFSI® soft mist inhaler with customizable flow resistance is thus important for predictable aerosol delivery to the lungs.

The post Assessing the variability of in silico lung deposition predictions when inhaling from soft mist inhalers with various air flow resistances first appeared on Resyca.