Abstract: The present disclosure relates to a process for manufacturing an oral pharmaceutical dosage form including: mixing an active pharmaceutical ingredient (API) and surfactant into a blend; feeding the blend into a processor that applies heat and shear forces at a temperature within a range of approximately equal to the melting point of the surfactant to 3° C. below the melting point of the surfactant so as to form API granulates; and formulating the API granulates into a dosage form. The disclosed technology provides a surprisingly effective and economical means for producing high dose solid dosage forms containing poorly soluble APIs with minimal excipient burden.