How to solve cosmetic manufacturing scale up issues

How to scale up cosmetic manufacturing

Products start by being developed in a laboratory; usually in samples of 100-200g. It is a big step to take product from 200g to 100kg. This is undoubtedly the biggest difference the product will experience, especially since such a difference in quantity will involve very different machinery than the 200g sample. Just because a formula can be made and is stable in a laboratory sample is no guarantee it will be stable, and suit manufacturing methods, when it reaches pilot batches or full-scale production. It is a very big risk for a company to prepare a bulk production batch without taking incremental steps from a very small lab sample, to large lab sample, to pilot batch, to full scale manufacture. Different equipment is often needed at each step, along with different mixing speeds and times, batches of materials (same supplier) and heating and cooling times. 

Learn more about the scale up steps in cosmetic manufacture with our blog:

Manufacturing cosmetics: How to manage scale-up.
Watch how to perform scale up steps easily and accurately with the right equipment in this video.
Watch steps to cosmetic manufacturer here. 
 

Can you skip steps in cosmetic manufacturing scale up?

The short answer is no. It can be tempting for companies to try to skip scale-up steps or see it as an unnecessary time or expense – but there is nothing cheap or quick about a product recall. The relatively small investment you make in suitable scale-up and stability programs is a fraction of what it would cost a company in product, distribution contracts, advertising and image if they ever have to go through a product recall. Suitable scale-up and stability programs safe-guard companies from having to experience a product recall. 

To avoid significant issues and product losses, scale up should be done in 10-20x increments maximum at each step. 

Learn more with our blog: Who’s responsible for faulty cosmetic products?
 

What should a cosmetic manufacturing scale up schedule look like?

Here is an example of a minimum test schedule for personal care products (including cosmeceuticals).

Note: this minimum schedule holds low-moderate risk of long term stability failure and may not be considered enough evidence to support a proposed 2-3 year shelf life for some product types by regulators. In some regions, and for some product types, you may need to hold off for 6 months minimum results at each step. 

Happy formulating!