Scale-Up – Early Phase

During formulation development, the wide variety of formulation compositions assessed typically requires very small batch sizes (≤5 L).

While MedPharm generally recommends formal process development or process assessment, our Subject Matter Experts can leverage experience
with similar product types (e.g., creams, sprays, solutions) to select lower-risk manufacturing approaches.

As with any strategy, associated risks are clearly defined and discussed with the client prior to work commencement.

Scale-Up – Late Phase

Once batch sizes exceed 50 L (UK site limit) and programs advance into later-stage clinical or registration manufacturing,
it is critical that the manufacturing process is fully understood and scalable.

To further minimize scale-up risk, MedPharm employs the same Axomatic manufacturing platforms from 10 L through 1,500 L at our US site.
This enables tight control of scale-dependent variables and greater precision when selecting final manufacturing methods.

Stages of Process Development and Scale-Up

  • Product analytical method development
  • Process development
  • Confirmatory, scale-up, or toxicology batch manufacture
  • ICH stability testing

Laboratories

  • ~3,500 sq ft (UK) and 100,000 sq ft (US) of purpose-built laboratories
  • Qualification and calibration of all instruments and equipment
  • SOPs defining use, maintenance, and calibration

Over 25 Years of Expertise

  • Established in 1999, MedPharm is internationally recognized for expertise in topical and transdermal drug development.
  • Regulatory authorities in Europe, Japan, and the United States recognize MedPharm as Subject Matter Experts.
Scientist performing pharmaceutical process development and scale-up using bench-scale mixing equipment

Scientific Staff

  • MedPharm’s process development and scale-up teams bring extensive experience across a wide range of formulation types.
  • Subject Matter Experts are available to support regulatory meetings, information requests (IRs), deficiency letters (DLs), and scientific justifications.

Quality, Data, and Reporting

  • All R&D activities conducted under MedPharm’s Quality Management System (ICH Q10 compliant)
  • MasterControl electronic Quality Management System (QMS)
  • Professional study plans, protocols, and reports
  • Data stored in a qualified Electronic Content Management System (ECMS)

Learn More

Explore the science behind MedPharm's scale-up and process development capabilities through case studies, scientific publications, and technical resources.

Cost-Effective Process Development Delivers Critical Clinical Trial Supply

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Resolving Scale-Up Stability Challenges Through Process Development

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Excipient Selection in Topical Process Development

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Establishing a Rigorous and Robust Approach to Topical Drug Product Process Development: Part I

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Establishing a Rigorous and Robust Approach to Topical Drug Product Process Development: Part II

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QbD Strategies to Secure the Scale-Up of Semi-Solid Topical Formulations

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Topical Development - Fast Tracking Your Way to Success

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