Manufacturing Partners / Scale-Up Philosophy
Scale-up philosophy for DermisIQ production.
Our approach to scale-up is built around stability, manufacturability, and repeatability. DermisIQ concepts are engineered to transition smoothly from lab sample to pilot run to full commercial production with minimal adjustment. This page outlines how IQ Labs LLC evaluates and executes each phase of scale-up alongside our manufacturing partners.
A controlled, data-informed scale-up model.
Scale-up is approached as a progression of validation steps rather than a single leap from lab bench to production tank. Each milestone is used to confirm stability, equipment alignment, and real-world performance before increasing volume.
- • Lab → Pilot → Validation → Commercial scaling
- • Emphasis on texture, viscosity, and long-term integrity
- • Collaboration on equipment constraints & fill-line behavior
- • Data-driven adjustments only when truly necessary
Pilot runs — bridging concept and production.
A pilot run allows us to confirm that the selected architecture behaves consistently when moved to real production equipment. This stage is especially important for emulsions with specific sensorial or structural expectations, such as DermisIQ’s soft-matte profiles.
- • Typically performed at the lowest feasible batch size
- • Identifies any shear, heat, or mixing nuances early
- • Offers a practical look at fill behavior, cooling profile, and appearance at scale
- • Results inform any final micro-adjustments before validation runs
Validation lots — confirming repeatable execution.
A validation lot is the proof point that the architecture can be produced consistently, repeatedly, and within target specifications. At this stage, both sides focus on ensuring long-term reliability rather than modifying the formula.
- • Confirms the architecture is stable and manufacturable
- • Viscosity and appearance matched to lab reference
- • Evaluates batch uniformity, mixing, and shear distribution
- • Supports forecasting and commercial planning
Commercial scaling — building volume with stability.
Once validation is complete, scale-up focuses on predictable volume growth without sacrificing texture, stability, or filling consistency. DermisIQ architectures are designed with this stage in mind from the beginning.
- • Collaboration on capacity planning & annual volume forecasts
- • Alignment on mixer sizes, fill lines & packaging SKUs
- • Ongoing stability observations to confirm long-term batch behavior
- • Periodic reevaluation of raw material availability and supplier continuity
Fill-line behavior & packaging compatibility.
We prioritize packaging systems that balance texture integrity, protection, and manufacturability. Scale-up includes confirming that the architecture performs predictably across the manufacturer’s preferred lines.
- • Verification of fill temperature windows and cooling behavior
- • Assessment of airless pump/tube/jar compatibility with viscosity and payoff
- • Monitoring for unexpected aeration or structural shifts during fill
- • Alignment on QC checkpoints for each packaging system
Addressing thermal & mechanical sensitivities.
Some DermisIQ architectures—especially those involving encapsulated systems or specific sensorial profiles—may have preferred handling windows. These parameters are never rigid, but they help preserve the intended performance profile when scaling.
- • Collaboration on upper/lower heat thresholds during emulsification
- • Review of shear intensity tolerance for structural components
- • Adjustment of cooling curves to preserve final texture
- • Identification of any interactions affecting encapsulated systems
Building stable, long-term manufacturing partnerships.
Our scale-up philosophy is designed to protect product integrity, reduce risk, and support manufacturer-aligned growth. By approaching scale-up as a structured, data-driven progression rather than a single step, we ensure that DermisIQ architectures remain consistent, stable, and commercially reliable at every volume.
This model adapts to each partner’s equipment, SOPs, and operational realities. Final parameters are always confirmed collaboratively during pilot and validation runs.