A paradigm shift in pharmaceutical manufacturing: the benefits of continuous production
Continuous manufacturing represents a fundamental shift in the pharmaceutical industry’s approach to production. In contrast to conventional batch processing, where each production stage is carried out individually and at separate times, continuous production involves a seamless process flow – from the feeding of raw materials right through to filling.
This not only enables a significant reduction in production times but also allows for continuous quality control through integrated process analytical technology (PAT).
In the customer project described, the introduction of continuous manufacturing processes enabled a significant leap forward in terms of efficiency, product quality and sustainability.
In addition to cost reduction and a shorter time-to-market, the focus was particularly on GMP compliance, containment, automation and sustainable energy use.
Fully integrated raw material feeding is a key aspect of this system and forms the basis for a stable, safe and highly flexible manufacturing process.
Efficient raw material feeding: from emptying big bags to safe conveyance
In the first and second process stages, the focus is on the safe, dust-free and GMP-compliant transfer of raw materials – a key component of any continuous production of pharmaceutical products. The raw materials, delivered in big bags, pass through a meticulously designed system that offers maximum safety and availability even in confined spaces. A distinctive feature of the project was the innovative gantry design, which played a key role in reducing the complexity of the assembly process.
Key components of the big bag emptying stations:
- Connection system for dust-free transfer to the suction shoe
- Support table for load bearing
- Agitator paddles to aid discharge of products with poor flow properties
- Sturdy frame with pneumatic clamping device
- Track carrier with chain hoist and lifting gear
Special features of the project:
- 5-bay cantilever gantry with 3 gantry units and two cross-braces – enables space-saving installation
- AAS-EF system with two-hand lever operation and integrated dust extraction filter
- In-line screening machine for protective screening
- Mobile transport trolley for cleaning in a separate washroom
Conveyor system featuring the ProClean Conveyor (PCC) from HECHT:
- Flow-optimised pipework system
- Slightly conical separation tank for improved discharge
- ViwateQ surface finish to prevent product adhesion
- Discharge flap with pneumatic vibrator to prevent bridging
- Integrated weighing system for continuous, precise dosing
Precision right down to the very last step: precise dosing for optimum product quality
Continuous production does not end with the transport of raw materials – on the contrary: the final step, the precise dosing into the mixer, is crucial to the homogeneity and effectiveness of the end product.
In this customer project, five high-precision differential dosing machines undertake this demanding task.
They ensure that precisely defined quantities of the powdered raw materials are fed evenly and synchronously into the continuous mixer.
This method of dosing not only ensures a consistently high product quality but also supports process stability and traceability – two key requirements of the pharmaceutical industry. By combining weighing and dosing technology with continuous feedback, the process becomes not only controllable but also actively manageable.
Key elements of the final process step:
- Five differential dosing machines
- Precise, continuous dosing with high throughput
- Seamless integration into continuous mixing technology
- Optimised process control through supporting weighing technology
- The basis for consistently high product quality and process reliability