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AbstractHigh-dose API powders which are to be tableted by direct compression should have high compactibility and compressibility. This note reports on a novel approach to the manufacture of crystalline powders intended for direct compaction with improved compactibility and compressibility properties. The poorly compactable API, chlorothiazide, was spray dried from a water/acetone solvent mix producing additive-free nanocrystalline microparticles (NCMPs) of median particle size 3.5 µm. Tablets compacted from NCMPs had tensile strengths ranging from 0.5 to 4.6 MPa (compared to 0.6-0.9 MPa for tablets of micronised CTZ) at compression forces ranging from 6 kN to 13 kN. NCMP tablets also had high porosities (34-20%) and large specific surface areas (4.4 to 4.8 m 2 /g). The time taken for tablets made of NCMPs to erode was not statistically longer (p>0.05) than for tablets made of micronised CTZ. Fragmentation of NCMPs on compression was observed. The volume fraction of particles below 1 µm present in the suspension recovered after erosion of NCMP tablets was 34.8±3.43%, while no nanosized particles were detected in the slurry after erosion of compacted micronised CTZ.Keywords: spray drying, tabletability, specific surface area, nanocrystalline microparticles, erosion, This work presents SD/crystallisation of NCMPs composed of chlorothiazide (CTZ), a highdose API, previously shown to be crystalline when SD (Corrigan et al., 1984). The tabletability and erosion characteristics of NCMPs is assessed and compared to conventionally processed powders. 4 SD of CTZ (Sigma, Germany) samples using conditions as outlined in table 1 was performed using a Büchi B-290 Mini Spray Dryer (Büchi 93001 en). Tablets (n=10) were compressed using a MTCM 1 tablet press (GlobePharma, USA), supplied with concave 10 mm diameter tooling. Tablets (n=10) were subjected to hardness test using Dr. Schleuniger-6D tablet tester (Pharmatron, UK). Erosion studies were performed in a vertically held glass vial (7.5x2 cm), equipped on the bottom with a 2 mm wire mesh and a tubing pumping in and out erosion medium (15 ml of 0.1M HCl at 37 ˚C) at the flow rate of 30 ml/min. Erosion time was defined as the time when all tablet fragments have passed through the wire mesh. Obtained suspensions were introduced to wet laser diffraction particle size analysis performed in 0.1 M HCl using a Hydro µP attachment with no ultrasound, using the pump speed of 1000 rpm and initial obscuration of 20±2%. Solubility studies of CTZ in solvents were carried out in a shaking water bath at 50 rpm, for 24 hours in 25 ˚C. Excess of CTZ was loaded into 10 ml glass vials, suspended in 5 ml of the solvent and vials hermetically s...