Investigational drugs are increasingly becoming less soluble in aqueous media thus presenting real challenges during development. Previous work has successfully demonstrated the manufacturing of pharmaceuticals using fluidized-bed (FB) impregnation of APIs onto porous carriers. This study demonstrates the usefulness of FB impregnation in formulating poorly-soluble drugs. We show that dissolution of Fenofibrate is greatly improved by FB impregnation onto Neusilin®, a synthetic amorphous form of magnesium alumino-metasilicate. We impregnate Neusilin® for range of loadings and examine Fenofibrate’s physical state. Dissolution of impregnated formulations is drug-loading dependent and loadings below 40% show great improvement (decrease) in release time compared to physical blend. Release times are further improved by milling. We also examine feasibility of co-impregnating Fenofibrate with additives and observe stability (1.5 years) of the amorphous form of Fenofibrate inside Neusilin®. This stabilization significantly improves Fenofibrate’s dissolution kinetics, making our formulation comparable to one of the current market formulations, TriCor® tablets.

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