In this presentation, we will first discuss basic spray-drying theory with attention to both aqueous and solvent-based systems, principles and techniques of atomization and particle separation, properties of spray-dried particles, types of spray dryers, and the process parameters affecting spray drying. Next, we will discuss how advanced techniques such as particle surface modification and microencapsulation can be used to improve powder flow-ability, produce water-dispersible powders from oil-based substrates, and provide shelf-stable powders containing viable probiotics or viruses. Finally, we will discuss the basic steps that an organization should take to investigate, innovative, develop, up-scale, and commercialize novel powdered products and how spray-drying technology is being used to help the DoD develop modern products such as exploding foil initiator compositions and dual-use secondary high-explosives/rocket propellants with improved insensitivity, power, handling safety, and lot-to-lot consistency.