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.