The pharmaceutical and healthcare industries are constantly moving through a period of unmatched changes. Oral administration of solid dosage forms is one of the most preferred route and is highly patient compliant as well as stable when compared to other dosage forms. However, the challenge of transition from a traditional manufacturing approach to continuous automated processing approach remains unmet. Continuous modifications in materials and manufacturing technologies are gradually being implemented in the industry to avail the benefits related to process automation, improved quality and reduced costs. Therefore, it is well accepted that there is a growing demand to discover alternative processes and design formulation strategies that can significantly improve powder processing techniques, granulation methods and equipment to ensure safe, reproducible and quality products are manufactured. The intended chapter presents an overview of the state-of-the-art research equipment, material handling techniques, process analytical technique implementation and 3D printing application strategies. It covers recent advances in techniques and processes at every stage of pharmaceutical product development and methods employed to troubleshoot the processing hurdles.