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A novel single step melt solidification technique was developed for ibuprofen. DSC studies designed to elucidate the effect of isothermal holding time showed that the extent of crystallization increased with holding time. Agitation speed and polyvinyl alcohol (PVA) were found to reduce the time required for crystallization. The excipient-free, non-disintegrating beads were irregular in shape with high mechanical strength and acceptable flowability. Slow dissolution from beads was attributed to the compactness and higher bond strength of the beads.