Scale Up Capabilities
Scale-up is one of the most commercially important stages in product development. A formula that performs well at bench scale will not always behave the same way in larger vessels, under different shear conditions or across longer processing times. At Global Cosmetic Developments (GCD), we help bridge that gap through pilot-scale batches and scale-up planning designed to reduce risk before full manufacturing begins.
Our approach considers the variables that often determine whether a product transfers cleanly from lab to factory, including vessel dynamics, order of addition, heating and cooling profile, mixing intensity, viscosity development, ingredient dispersion, air incorporation and filling behaviour. Addressing these factors early helps identify scale-sensitive issues before they become costly manufacturing setbacks.
Our pilot-scale service supports a smoother transition into contract manufacture by generating larger trial batches that better reflect real production conditions. These batches can be used to assess process practicality, support manufacturer discussions, generate bulk for evaluation or sampling, and build confidence that the formulation is ready for technical transfer.
Our Expertise
- Pilot-scale batch manufacture in 10 kg, 30 kg or 50 kg batch sizes, depending on formulation design and process requirements
- Practical scale-up guidance covering process order, mixing approach, temperature profile and critical handling points
- Identification of likely scale-sensitive risks such as aeration, viscosity shift, separation, poor dispersion or filling challenges
- Support for manufacturer handover discussions, including clearer technical expectations for first production trials
- Bulk-only pilot batches that can be used for evaluation, internal review, compatibility work or pre-launch sampling
- Up to two pilot-scale batches available for newly developed GCD formulations, where appropriate to the project scope
Whether you are preparing for first manufacture, troubleshooting the move from lab batch to bulk, or looking for a more credible route into contract production, our scale-up support helps reduce avoidable delays and build confidence before commercial manufacture begins. Please get in touch to discuss your formulation and scale-up requirements.