Analysts project that the global TPD market will grow from roughly $500 million in the mid-2020s to several billion dollars by the mid-2030s, implying CAGRs in the 20–35% range depending on methodology.
Within that wider opportunity, oral administration is expected to dominate commercial uptake, potentially accounting for 60% of revenue as convenient chronic dosing becomes the preferred mode of treatment when feasible.
For drug product developers, this convergence of scientific momentum, commercial expectations and a pronounced shift toward oral solid formats creates a clear mandate: build development and manufacturing strategies that can support low-dose, high-potency TPDs from first-in-human studies through commercialisation.
David O’Connell, Director of Scientific and Technical Affairs at PCI Pharma Services, reports.
Why TPDs demand low-dose precision
TPDs do not simply inhibit a protein’s activity; they recruit the cell’s own ubiquitin–proteasome system to tag and destroy disease-relevant proteins.
In molecular glues, a small molecule stabilises the interaction between an E3 ligase and a target, whereas PROTACs use a bifunctional design in which one end binds the target and the other engages an E3 ligase to trigger ubiquitination and subsequent proteasomal degradation.
Because degraders can act catalytically, disengaging from one substrate and binding another, they often achieve therapeutic effects at much lower doses than traditional occupancy-driven inhibitors.
That pharmacology underpins the frequent need for microdosing and low drug loads in oral TPD formulations: the active pharmaceutical ingredient (API) may represent only 1–5% (or less) of the final tablet or capsule.
At such low concentrations, small deviations in blend homogeneity, particle size distribution or process parameters can translate directly into clinically meaningful variability in delivered doses.
Content uniformity and process control have become central design constraints rather than late-stage checks.
Solubility and permeability: beyond brick dust
Many TPD candidates, particularly PROTACs, fall well outside the classical Lipinski “Rule of Five” space, combining high molecular weight and elevated lipophilicity with poor aqueous solubility.
In practice, they often resemble “brick dust” compounds with sluggish dissolution in gastrointestinal fluids and, in some cases, limited membrane permeability. This places them predominantly in Biopharmaceutics Classification System Class II or IV.
For oral developers, the first question is not simply whether a molecule can be formulated, but whether solubility, dissolution rate, permeability or a combination of these will be the primary barrier to in vivo performance.
The Developability Classification System helps by distinguishing between dissolution-rate-limited candidates (Class IIa) and those fundamentally constrained by solubility (Class IIb).
For Class IIa degraders, micronisation or nanomilling can improve dissolution by increasing the surface area and enhancing interactions between API particles and gastrointestinal fluids.
Class IIb molecules may require amorphous solid dispersion technologies (spray-dried dispersions or hot-melt extrusion) to raise apparent solubility and support adequate absorption.
These enabling approaches effectively embed the solubility solution into the drug product, adding further complexity to stability, scale-up and regulatory strategies.
Content uniformity at very low drug loads
Achieving uniform API distribution is critical for any oral solid product. However, the challenge becomes more acute when milligram-scale quantities of a potent TPD must be distributed throughout kilogram-scale blends.
Traditional approaches often cope well when API load exceeds about 10% w/w; however, many TPD formulations sit well below this threshold and are intrinsically prone to “hot spots” and underdosing if blending is not carefully engineered.
At these levels, a robust uniformity strategy is as important as the solubility solution itself.
Formulators frequently rely on trituration and geometric dilution to manage this risk. A concentrated premix of API and a suitable carrier or excipient is prepared, then progressively expanded using staged blending until the API is evenly distributed throughout the full batch.
Carrier-based strategies can further support uniformity at trace concentrations. Hydrophobic APIs may be preblended with excipients such as colloidal silica, which anchors fine particles onto a more flowable substrate before geometric mixing.
Depending on the API’s physical properties and the target dosage form, roller compaction or wet granulation can then embed the degrader into robust granules that resist segregation during transfer, compression and filling, providing the molecule’s stability profile can tolerate the associated process conditions.
Particle engineering and excipient strategy
Particle size and morphology strongly influence both biopharmaceutical performance and manufacturability in low-dose TPD products.
Micronisation and nanomilling increase the surface area of the API particles and can improve dissolution … but they often worsen flow and promote agglomeration or electrostatic interactions, especially when excipient particle sizes are not well matched.
Needle-like crystals, for example, may bridge, align or segregate differently than more equant particles, complicating both blending and downstream processing.
Roller compaction can also help to break up problematic crystal habits and generate more processable intermediates (if the API’s stability profile allows). In parallel, excipients must be treated as part of the control strategy rather than passive carriers.
The choice of grade, particle-size distribution, flow characteristics and binding behaviour all influence how effectively an excipient system can distribute a small amount of potent API through a much larger mass of material.
Hydrophobic or micronised APIs may require specifically chosen excipient combinations to mitigate segregation risk and maintain blend homogeneity during transfer, compression and filling.
Another processing strategy to overcome low-dose/difficult-morphology APIs is to dissolve them in a suitable solvent.
The API solvent is sprayed onto an inert powder blend using fluid-bed granulation; the solvent is subsequently removed during the drying phase, leaving the API bound to the carrier molecule.
A similar process to improve the solubility/bioavailability of an API is to solubilise the API in the relevant solvent with a stabilising polymer and spray dry the solution mix, thereby keeping the API in an amorphous form.
Early process and excipient gap analyses help to identify whether a given material set can realistically support the required dose strengths, potency classification and manufacturing route.
Addressing such constraints proactively reduces the likelihood of later reformulation and delays arising from poor content uniformity or inadequate process robustness in GMP settings.
Designing for manufacturability, containment and analytics
For TPDs, manufacturability and containment must be built into formulation design from the outset rather than considered after feasibility has been shown at bench scale.
Many degraders are classified as highly potent (OEL less than 10 µg/m3) or even ultra-potent (OEL less than 0.1 µg/m3) early in development — often based on limited toxicology data and conservative safety factors that reflect their catalytic efficiency and low clinical doses.
This potency profile drives the need for engineered processing equipment, making operations such as geometric mixing, repeated blending and contained transfers more complex and time-consuming in rigid or flexible isolators.
Scale-up amplifies these issues. Subtle changes in equipment geometry, powder movement or granulation behaviour can disrupt content uniformity in low-dose products.
Leveraging equipment trains that are geometrically similar across development and commercial scales, such as high-shear mixers and intermediate bulk containers designed with consistent angles and dimensions, can improve predictability and reduce the need for late redesign.
Throughout, formulation choices must balance process robustness, operator safety and patient practicality, so that the final dosage form remains suitable for clinical use while being feasible to manufacture at scale.
The same attributes that make TPDs attractive therapeutically (low doses and high potency) also raise the bar for analytical methods.
High-performance or ultra-performance liquid chromatography often suffices for many low-dose oral products, but further reductions in strength or drug load can push these techniques to their detection limits, especially for cleaning verification in multiproduct facilities.
In such cases, liquid chromatography–mass spectrometry may be required to achieve the necessary sensitivity and specificity for both product release and contamination control.
LC–MS brings its own development challenges, including the optimisation of ionisation conditions, detector settings and sample preparation to recover trace APIs from complex matrices or equipment surfaces, so analytical strategy must evolve in step with potency and dose decisions.
Looking ahead: designing degraders for development reality
As discovery teams refine degrader chemistry, newer candidates are becoming more potent, more selective and effective at lower doses.
At the extreme, microgram or submicrogram strength tablets may be impossible to manufacture consistently using conventional approaches, even before considering the containment demands associated with ultra-potent compounds.
These pressures highlight the importance of early dialogue between discovery, drug substance and drug product teams so that manufacturability, solubility, morphology and stability considerations inform lead optimisation rather than becoming late-stage barriers.
Future solutions may include modifying TPDs to incorporate larger carrier structures for easier handling, as well as embracing greater automation and robotics for synthesis, blending and filling when human-centred processes can no longer safely accommodate ultra-high potency.
For sponsors and partners supporting oral TPD development, success will come from integrating enabling formulation technologies, high-potency containment, sensitive analytics and scale-aware process design within a coherent, molecule-led strategy that keeps pace with the field’s rapid growth.
