From Concept To Market: Scaling And Manufacturing Semi-Solid Topical Drugs

Developing a semi-solid topical drug product demands a deeper level of scientific and process understanding than traditional solid dosage forms. Every choice — from excipient interactions to the order of ingredient addition — shapes the product’s microstructure, physical stability, and ultimately the patient experience. Because subtle processing shifts can alter drug release, texture, and long‑term uniformity, early formulation decisions carry significant consequences across clinical, scale‑up, and commercial phases.

A Quality by Design mindset is essential as teams navigate the unique challenges of scaling these systems. Equipment geometry, shear profiles, thermal control, and mixing efficiency rarely translate directly from bench to plant, creating risk for changes in emulsification, drug distribution, or air incorporation. A holistic, cross‑functional approach that integrates formulation science with engineering, quality, and manufacturing readiness is critical for de‑risking transitions and securing reliable production.

This session provides foundational insight into topical formulation development, key scale‑up considerations, and practical strategies for maintaining Critical Quality Attributes across the product lifecycle.