Formulation Research Development
Formulation and process development are key processes to achieve the best drug product possible. Both processes are required to control the drug product to the needed quality attributes so that each commercial batch is saleable.
- Formulation development involves both sourcing the most appropriate grade materials tailored for product design and assessment of the drug within the formulation. The reverse engineered formulation is used to assess the drug-excipient compatibility, initial stability and develop specifications.
- Our Process Development strategy deploys a systematic Design of Experiments (DoE) approach to how the product will be made which can be translated to scale at the manufacturing site of your choice. Deploying a Quality by Design (QbD) approach for all avenues of our development program, we ensure that the Critical Quality Attributes (CQAs) are controlled to optimize batch success rate and to be ready for your regulatory dossier. With a full understanding of current cGMP standards, the process development team can support many dosage forms, drug-device combinations and packaging configurations.
- Scale-Up Support W We also have a wide network of established manufacturers of various dosage forms we can recommend and engage, should you require help with.
- API physicochemical characterization
- Solubility and pH–solubility profiling
- Excipient compatibility studies
- Solid-state characterization (polymorph screening)
- Particle size and morphology evaluation
- Forced degradation studies
- Stability profiling under accelerated and stress conditions
- Formulation feasibility assessment
- Bioavailability and delivery feasibility screening
- Selection of formulation approach based on API properties
- Prototype screening for clinical and toxicology batches
- Container–closure compatibility assessment
- Extractables and leachables risk assessment
- Stability-indicating analytical method development
- Selection and analytical evaluation of reference listed drugs (RLDs)
- Reverse engineering and formulation deconstruction of generic products
- Q1/Q2 qualitative and quantitative formulation matching
- Screening and selection of API, excipients, and functional ingredients
- Development of prototype and lab-scale formulations
- QbD-based formulation design and optimization
- Identification of critical material attributes (CMAs)
- Optimization of formulation composition for target performance
- Solubility enhancement and stabilization strategies
- Development of controlled or modified-release formulations, where applicable
- pH, viscosity, osmolarity, and tonicity optimization
- Preservative selection and antimicrobial effectiveness optimization
- Device- and container-compatible formulation development
- In-vitro performance testing and comparison with reference products
- Formulation robustness and manufacturability assessment
- Excipient and packaging compatibility evaluation
- Short- and long-term formulation stability studies
- High-shear and low-shear mixing
- Homogenization and emulsification
- Milling and particle size reduction
- Solvent casting and film processing
- Hot-melt extrusion processing
- Lyophilization (freeze drying)
- Aseptic processing
- Sterile filtration
- Fill–finish operations
- Blow-Fill-Seal (BFS) technology
- Spray filling and device assembly
- Implant extrusion and molding
- In-process controls and validation support
- Process robustness and commercial readiness support