Spray drying can generate very fine powders for inhalable drugs and improve the bio-availability of solid dosage drugs using amorphous solid dispersion. However, spray drying is quite challenging to optimize and scale up. Many interacting parameters have a considerable impact on the product yield, residual solvent content, and particle size. We have demonstrated a novel model-aided workflow to optimize and transfer the process across three different Spray dryers for a sticky product. The material produced in this work has a very low Glass transition temperature resulting in adhesion of the product to the wall. Mechanistic models and CFD models have been developed across three different pieces of equipment. Mathematical models have been used to understand & optimize the impact of operating conditions on the product yield across the scale. The understanding developed using the workflow has enabled the production of API with greater than 80% yield across the scales.