MANUFACTURING & SCALE-UP
A considered path to manufacturing readiness
A project-led approach to process scale-up, quality documentation and packaging, with manufacturing scope confirmed for each collaboration.
Explore moreConnect the formulation to a repeatable process.
Plan process scale-up, packaging and documentation around the needs of oral films and freeze-dried tablets, with manufacturing scope confirmed for each collaboration.
Two Process Routes Transfer & Scale-up Packaging Development Quality & Project Records Common Questions
TWO PROCESS ROUTES
Build the process around the format.
Oral film process development
A typical route considers ingredient preparation, mixing and dispersion, coating, controlled drying, cutting and individual packing. The process must support the agreed unit dimensions, consistency and handling characteristics.
Freeze-dried tablet process development
A typical route considers solution or suspension preparation, controlled filling, freezing, primary and secondary drying, then protective sealing. Cycle and pack choices depend on the formulation and intended product.
TRANSFER & SCALE-UP
Reduce uncertainty before increasing scale.
01
Review process readiness
Bring together the selected formula, critical material information, prototype findings and the intended product specification.
02
Plan pilot work
Identify equipment and scale differences, sampling points and the process variables to examine. Agree the purpose and acceptance criteria of the trial.
03
Evaluate repeatability
Review unit consistency, handling, moisture-related attributes and other agreed checks. Investigate variability before treating a process as ready.
04
Align packing & documentation
Confirm protective packaging, pack-opening experience, records, responsibilities and any additional evidence needed for the next stage.
PACKAGING DEVELOPMENT
Protection is part of the product.
Barrier & seal integrity
Select candidate packaging against moisture, oxygen or light sensitivity where relevant. Evaluate the seal and the product together; a barrier material alone does not establish shelf life.
Handling & opening
Consider strip release, tablet fragility, transport and the way a user opens the unit pack. Sachet or blister concepts need practical evaluation with the intended product.
Pack & storage compatibility
Use the candidate pack in the agreed storage study. Review changes in appearance, moisture-related behavior, ingredient markers and handling before defining storage instructions.
QUALITY & PROJECT RECORDS
Agree what will be checked and documented.
Documentation and testing are scoped to the product, development stage and intended market. Facility credentials and supply responsibilities should be reviewed for the specific manufacturing arrangement.
- Ingredient and packaging specifications, identity and traceability requirements
- Agreed in-process checks and a sampling approach
- Product attributes, evaluation methods and acceptance criteria
- Batch and process records appropriate to the agreed stage
- Deviation review, change communication and technical handover responsibilities
COMMON QUESTIONS
Before a manufacturing discussion.
Can you quote a minimum order quantity or production capacity?
These depend on the formulation, unit size, selected process, pack and manufacturing arrangement. Share your expected volumes so feasibility and supply scope can be reviewed.
Can the product use our own branding and pack design?
Branding and artwork can be part of the packaging brief. Pack suitability, label content and the responsibilities for market-specific review must be agreed separately.
Are all products suitable for the same production route?
No. Ingredients, dose, sensitivity and performance targets can change the equipment, process conditions and pack required. Prototype success alone does not establish manufacturing readiness.
What information helps you review a transfer project?
The formula and material specifications, existing process description, batch or prototype data, known issues, candidate packaging, target market and expected supply volumes.