This white paper highlights how continuous twin-screw granulation (TSG) accelerates pharmaceutical process development and ensures reliable scale-up. Unlike batch methods, TSG enables flexible production, reduced material use in R\&D, and consistent product quality. Key parameters—liquid-to-solid ratio, throughput, screw speed, configuration, and temperature—directly influence granule size, density, and drug release. Scale-up depends on controlling filling level and residence time within the screws, with attention to cooling demands at larger scales. Avoiding fixed screw designs, feed inconsistencies, and inadequate cooling are critical. Properly managed, TSG delivers faster development and predictable scale-up.

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