Laser drying of pharmaceuticals and nutraceuticals: principles, applications, and AI-assisted future technologies

Laser Assisted Drying (LAD) is an emerging next-generation dehydration technology for stabilizing pharmaceutical and nutraceutical formulations, particularly those containing thermolabile biomolecules and bioactive compounds. Unlike distinct conventional methods, such as freeze drying and spray drying, which are often limited by long processing times, high energy consumption, thermal degradation, and reduced product quality/quantity, LAD provides rapid, localized energy transfer via controlled laser irradiation, enabling efficient moisture removal with minimal thermal stress and improved preservation of biological activity. This review examines the fundamental principles of laser drying (LD), including photon–material interactions, energy absorption mechanisms, thermal and non-thermal effects, moisture-removal pathways, and the influence of key laser parameters on drying performance. It also discusses various laser systems, including CO2, Nd:YAG, fiber, diode, pulsed, and continuous-wave lasers, and evaluates their suitability for pharmaceutical applications. The advantages and limitations of LAD are highlighted, with emphasis on its ability to preserve proteins, peptides, vaccines, probiotics, mRNA formulations, and nutraceutical bioactive compounds. Attention is given to its application in Host-directed therapy (HDT), where stabilization of immunomodulatory agents, biologics, nano-formulations, and inhalable delivery systems is essential for therapeutic efficacy. The review further explores the integration of artificial intelligence (AI), machine learning (ML), process analytical technology (PAT), quality-by-design (QbD), and digital twin frameworks to predict critical quality attributes (CQAs), optimize process parameters, and support intelligent pharmaceutical manufacturing. LAD is rapidly becoming the premier drying platform for stabilizing thermolabile drugs, biologics, nutraceuticals, and host-directed therapies. When integrated with AI-driven process optimization and advanced manufacturing frameworks, LAD has the potential to support intelligent, scalable, and precision-oriented pharmaceutical production.