The therapeutic potential of inhaled biologics is limited by protein instability during aerosolization, which can cause aggregation and increase immunogenicity risks. This study aims to identify key molecular and formulation parameters that minimize the aggregation of antibody Fab fragments during vibrating mesh nebulization. A set of 14 engineered Fabs with a broad range of melting temperatures (Tm 60-90°C) were nebulized using two different commercial vibrating mesh devices. We systematically assessed the impact of Fab thermostability, protein concentration (10-80 mg/mL), formulation excipients, and nebulizer device on the formation of high molecular weight species (HMWS) and subvisible particles (SVP). Aerosol characteristics, including fine particle fraction (FPF) and output rate, were also evaluated. High intrinsic thermostability and high protein concentration were identified as the two most critical factors for preventing aggregation. Fabs with a Tm above 80°C demonstrated exceptional stability with negligible aggregation. We attribute this effect to a correlation of high Tm with a higher resistance against unfolding and therefore a better tolerance against nebulization-induced stresses, in particular air/liquid interfacial stress. Counterintuitively, increasing the protein concentration from 10 mg/mL to 80 mg/mL suppressed aggregation for all Fabs, which had the highest benefit for Fabs with lower thermostability. This effect can at least in part be explained by a saturation of the air/liquid interface at higher Fab concentrations. While higher concentrations modestly reduced nebulizer output rates, the overall inhalable protein output (mg protein/min) was significantly enhanced. In comparison, full-length monoclonal antibodies showed poor aerosolization performance at high concentrations. Our findings provide clear guidance for developing inhaled Fab therapeutics. To ensure stability and minimize aggregation, priority should be given to selecting Fabs with high thermostability (Tm > 80°C) and formulating them at high concentrations (≥ 40 mg/mL). These strategies are expected to mitigate aggregation-induced immunogenicity and concomitant safety risks, facilitating the development of the next generation of inhaled protein drugs.
The pharmaceutical industry is undergoing a rapid digital transformation. These changes are reshaping drug substance and drug product development and manufacturing, creating both opportunities and challenges that span pharmaceutical sciences, data science, and automation engineering. However, significant skills gaps persist, limiting the sector's ability to fully leverage digital technologies and sustain innovation. This paper explores the shifting digital and data science skills needs within the pharmaceutical industry, with a focus on industrial pharmacy and pharmaceutical sciences in the UK and Europe. We examine the key technological transformations reshaping the sector, the evolution of job roles, and the attributes required of the future workforce. Building on these insights, we propose an integrated approach to skills development that spans the entire career lifecycle - from embedding digital competencies in higher education to supporting lifelong learning through flexible, industry-aligned continuing professional development. Addressing these skills gaps requires coordinated action from academia, industry, and policymakers. By fostering a collaborative, interdisciplinary, and adaptive learning ecosystem, the pharmaceutical sector can equip its workforce to thrive in a rapidly changing landscape and continue improving global health and wellbeing.

