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Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
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Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
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Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications

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Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications
Journal Article

Freeze-Drying as a Tool for Preparing Porous Materials: From Proof of Concept to Recent Pharmaceutical Applications

2025
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Overview
Freeze-drying (FD) is the most extensive drying technique in pharmaceutical and biopharmaceutical industries. It relies on three main steps: freezing, primary, and secondary drying, where the sample is frozen and then dried by ice sublimation. FD possesses several features, mainly its suitability for heat-sensitive materials and its ability to produce dry products with improved physicochemical characteristics. Although FD is a gentle drying process, it can cause numerous stresses that induce chemical and physical instabilities. Herein, the addition of suitable excipients along with optimizing the process parameters is critical in attaining lyophilizates with high-quality attributes. Besides, the freeze-drying method has been explored as a unique route to produce porous materials with different applications. This work aims to dismantle the basics of freeze-drying and its role in developing porous materials, mainly amorphous and co-amorphous solid-dispersions, orodispersible tablets and films, as well as porous dressings and 3D scaffolds for effective wound healing and tissue engineering, respectively. The challenges and limitations of lyophilization have also been addressed. Highlights Freeze drying is a propitious drying method, especially for thermolabile materials. The freeze-drying technique can form products with high-porous features. The successful lyophilization cycle depends on understanding both the formulation variables and the process parameters. Recent studies have shown that lyophilization under controllable conditions can develop porous materials with different applications and high-quality attributes. Graphical Abstract