Scaling Up Oral Solid Dose Manufacturing for Late-Phase Success

How to select the right CDMO, translate lab data into scalable OSD processes and apply QbD principles to avoid delays in late-phase manufacturing.
March 25th 2026
15:00 (GMT) / 10:00 (ET)
OVERVIEW

As programmes progress into Phase 2b and Phase 3, oral solid dose development faces increased pressure. Batch sizes grow, processes become more sensitive and regulatory expectations tighten. This creates a need for stronger process understanding and a clearer view of how early laboratory decisions influence late phase performance.

This presentation explores the scale sensitive steps that underpin consistent product quality, including blending, granulation, compression and coating. The speakers will outline how data generated at laboratory scale can be translated into robust processes that hold up under greater mechanical, material and environmental demands. Approaches using QbD and DoE will be highlighted to show how data driven frameworks support process design and control.

 

Attention will also be given to planning for late phase requirements earlier in development. Practical insights from real projects will show how development and manufacturing teams can work together to reduce variability, anticipate risk and build processes that are ready for validation and commercial readiness. This will be particularly valuable for organisations preparing to move from early clinical work into late phase manufacture or refining their current scale up strategy.

Addressed Challenges

01Managing process robustness, material variability, and equipment selection as OSD programmes scale from laboratory into late-phase manufacturing environments.
02Applying QbD and DoE data effectively to inform late-phase process design and maintain control as batch sizes and regulatory scrutiny increase.
03Translating laboratory-scale data into robust, scalable OSD processes that hold up under the mechanical, material, and environmental demands of late-phase manufacture.

WHAT YOU WILL LEARN

01Understand the importance of selecting the right CDMO for late-stage OSD scale-up and what capabilities and experience to look for in a development partner.
02Learn how early scale-up planning by the right CDMO partner can prevent costly delays and process failures during late-phase and commercial manufacture.
03Discover how laboratory data can be translated into robust, scalable OSD processes using Quality by Design principles to support regulatory submissions.
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SPEAKERS
Dipak Gordhan
Associate Director of Manufacturing Operations
Dipak brings more than a decade of hands-on experience in drug product development and manufacturing. Currently Associate Director of Manufacturing Operations at Upperton Pharma Solutions, he leads clinical-scale production and scale-up initiatives from Phase 1 through late-stage trials. He began his career in formulation development in 2013 and advanced through roles in technical transfer, equipment qualification and commercial-readiness activities. Dipak holds a Bachelor’s in Pharmaceutical & Cosmetic Science from De Montfort University and is completing his PhD in Pharmaceutical Sciences at University of Nottingham.
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Nathan Collingwood
Principal Scientist
Nathan serves as Lead Principal Scientist at Upperton Pharma Solutions, where he specialises in technical transfer and scale-up of pharmaceutical dosage forms from development into clinical manufacture. He holds a degree in Chemistry from University of Glasgow and brings more than a decade of both hands-on lab experience and manufacturing insight to his work. In his role he guides analytical method transfer, and process implementation for early-to-late-stage clinical programmes.
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