From Lab to Mass Production: Smooth Scale-Up of ODF Manufacturing Parameters

Introduction
In ODF (oral dissolvable film) projects, formulations and process parameters validated at the laboratory stage often need to be replicated in pilot and commercial-scale production. However, during scale-up, issues such as reduced film quality, lower yield, and unstable processes can arise. More importantly, if your target markets include supplements and pharmaceuticals, the scaled-up equipment must continue to meet pharmaceutical-grade GMP standards to support product registration and international export.

1. Common Scale-Up Challenges

1. Inconsistent Drying Results
   Differences in duct design and temperature distribution can lead to uneven film surfaces and content uniformity issues.
2. Reduced Coating Precision
   Wide-width coating can cause edge buildup or thinning in the center.
3. Difficult Tension Control
   Longer web paths increase the risk of tension fluctuations, leading to film stretching or deformation.

2. Strategies for Smooth Scale-Up

• Pilot-Scale Bridge Equipment – Before moving to full production, use a pilot machine (such as the MJ150-L) with the same coating and drying principles as the mass-production model to validate scalability.
• Unified Control and Data Systems – Ensure parameters such as temperature, speed, and tension can be traced and replicated across lab, pilot, and mass-production stages.
• Step-by-Step Optimization – Fine-tune critical factors like duct airflow, coating gap, and liquid feed pressure during the pilot phase before scaling up.

3. HUANGHAI’s Scale-Up Advantage

The MJ150-L (pilot-scale) and MJ150 (mass-production) are both pharmaceutical-grade GMP machines:

• Comply with dual standards for supplement and pharmaceutical manufacturing
• Enable seamless parameter transfer to reduce trial-and-error costs during scale-up
• Provide full data recording and export for regulatory and audit requirements

Conclusion

Smooth parameter scale-up not only accelerates time-to-market but also minimizes rework and waste caused by mismatches in process or equipment. Choosing a pharmaceutical-grade scale-up solution ensures long-term compliance and production stability for ODF products in both supplement and pharmaceutical markets.