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.

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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.

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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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Journal: Expert Opinion on Drug Delivery , Volume 20(8), 2023

Abstract: Soft mist inhalers (SMIs) are propellant-free inhalers that utilise mechanical power to deliver single or multiple doses of inhalable drug aerosols in the form of a slow mist to patients.

Compared to traditional inhalers, SMIs allow for a longer and slower release of aerosol with a smaller ballistic effect, leading to a limited loss in the oropharyngeal area, whilst requiring little coordination of actuation and inhalation by patients.

Currently, the Respimat® is the only commercially available SMI, with several others in different stages of preclinical and clinical development.

Areas covered: The primary purpose of this review is to critically assess recent advances in SMIs for the delivery of inhaled therapeutics. Expert opinion: Advanced particle formulations, such as nanoparticles which target specific areas of the lung, biologics, such as vaccines, proteins and antibodies (which are sensitive to aerosolisation), are expected to be generally delivered by SMIs.

Furthermore, repurposed drugs are expected to constitute a large share of future formulations to be delivered by SMIs. SMIs can also be employed for the delivery of formulations that target systemic diseases.

Finally, digitalising SMIs would improve patient adherence and provide clinicians with fundamental insights into patients’ treatment progress.

Reference

The post Advances in soft mist inhalers first appeared on Resyca.

At Medspray in Enschede, The Netherlands, the manufacturing of our soft mist spray nozzle units takes place under clean room conditions on an automated production line, upscaled for high volumes. Several robotic machines assemble the silicon nozzle plates into their plastic holders. The nozzle plates are made of the same material that is used to make computer processor or memory chips, only in this case it is only a mechanical structure, no electronics are involved. The dimensions are mind-boggling tiny, each spray nozzle plate has approximately 100 pores of 2 micron, which is 35 x smaller than the diameter of a human hair. The pores are located on 50 micron diameter membranes of less than 1 micron thickness, to reduce the viscous losses and to keep the spray pressures in our inhaler devices to a minimum.

The resulting spray nozzle units are being assembled into our soft mist inhaler devices. Each spray nozzle unit is tested in line at Medspray to ensure the required quality. When Resyca’s purely mechanical soft mist inhaler devices push the aqueous formulation through these nozzle pores, Rayleigh jets emerge, resulting in 4 micrometer diameter primary droplets, resulting in a slow moving inhalable aerosol cloud. The high-tech nozzle technology enables relatively low-tech inhaler devices, which work purely mechanical and at a relatively low pressure of around 25 Bar.

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