Process development entails the development, optimization and scale-up of a chemical synthetic route that can be transferred into a cost-effective, safe, and reproducible manufacturing process. The development comprises three stages: bench-scale, kilo-scale, and pilot-plant scale, with process validation at each stage. During the initial stages, the most robust synthetic route is investigated, optimized and validated, followed by scale-up of the chosen route to kilogram scale in the Kilo lab. Key factors that are considered during each stage include the temperature of the reaction, reaction time, number of steps, product loss minimization, work-up and product isolation procedure, waste management and environmental impact, reproducibility and costs involved. When the above-mentioned are satisfied, the process gets transferred to the pilot plant where aspects such as scalability, safety, and quality are further evaluated. In each stage of development, total process cost is measured, which ultimately contributes to the total API product cost (material cost + conversion cost). Results and Discussion 4,7-Dichloroquinoline ( ) is an important component of several antimalarial drugs and is therefore a major driver of cost in the production of amodiaquine (3), as it accounts for over 40% of the raw material costs. Thus, a robust, cost-competitive process for the production of amodiaquine (3) would require preferred pricing from commercial suppliers. This, however, would be a temporal solution as there would be no internal control of costs, hence, an equally cost-competitive process for the manufacture of 4,7-dichloroquinoline (5) needed to be developed in-house for continuous raw materials supply without interruption during ADQ (3) production.