β-carotene, the precursor of vitamin A is a potent antioxidant that protect from chronic diseases including cardiovascular, cancer and eye diseases. Administration of β-carotene in the form of aerosol by pulmonary route will help to maintain the respiratory mucosa which otherwise can undergo severe morphological and functional changes as a consequence of vitamin A deficiency; also this method will help to enhance the bioavailability of β-carotene. For aerosol preparation, spray drying (SD) and spray freeze-drying (SFD) of β-carotene were studied with different core to wall ratios (1:10, 1:25 and 1:50) using HP-β-cyclodextrin as wall material. The aerosols prepared by SFD showed porous structure (8.3-9.3 µm) with low density and free flowing behaviour whereas SD produced cohesive powder with smooth surface (9.3 to 9.6 µm). All formulations exhibited good mass median aerodynamic diameter (MMADt) of 3.75 to 6.96 µm; % emitted dosage was found to be higher in SFD aerosols (57-60%) compared to SD (51-52%) with controlled release of β-carotene from SFD powder. Since particle density, size and morphology strongly affect particle deposition in lungs, therefore this approach can be conveniently scaled up for pulmonary supplementation of food bioactives.