Highlights

• Geldart group C ibuprofen particles were silica dry coated to enable fluidization.

• Aeration testing and flow function coefficient were indicative of fluidizability.

• Dry coated ibuprofen powders could be fluidized and polymer film coated.

• Polymer suspensions with stabilized colloidal silica led to reduced agglomeration.

• Scalable coating conditions were determined for the micronized ibuprofen powders.

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