As the morphology of spray dried aqueous mannitol solutions is strongly influenced by the scale of the used spray dryer or more correctly by the droplet size generated in the spray dryer the purpose of this work is to carefully study and compare the morphologies and underlying particle formation mechanisms on lab and pilot scale. Therefore drying experiments of 15% [w/w] aqueous mannitol solutions were performed on a lab and pilot scale spray dryer at different outlet temperatures. The obtained spray dried products are intended to be used as carrier particles for pulmonary drug delivery. In order to show that the morphology is highly dependent on the initial droplet size, irrespective of the size of the used spray dryer, droplets of different size were dried in the pilot scale spray dryer at different air outlet temperatures. Additionally the influence of feed temperature on particle morphology was studied. For small droplets crystallization from a highly viscous liquid or even water-free melt is observed, leading to rough particles at high outlet temperatures and smooth particles at low temperatures. When drying larger droplets, however crystallization obviously starts from a more diluted solution leading to rougher surfaces, containing larger single crystals at lower outlet temperatures than at higher ones. For large droplets an increase in the mannitol solution feed temperature leads to particles of comparably rougher surface. No influence of feed temperature was observed for smaller droplets. (C) 2013 Elsevier B.V. All rights reserved.