Düsseldorf (Germany), April 20, 2016 – The pharmaceutical industry is looking at continuous processing to improve production quality in an efficient and cost-effective way, and to comply with the increasingly stringent manufacturing acceptance criteria put in place by the regulatory authorities.

With lower upfront investment costs compared with traditional facility design and build approaches, lower energy and resource requirements, and enhanced quality, portable, continuous, miniature and modular (PCMM) pod-based mini factories look to be the solution for many of the pharmaceutical industry’s flexibility needs. Additional benefits include increased OEE, optimized R&D, multiple formulations and flexible batch sizes, reduced materials and cleaning costs.

ISPE Award for PCMM Manufacturing Platform

Pfizer, GEA and G-CON scooped the International Society for Pharmaceutical Engineering (ISPE) 2016 Facility of the Year Award (FOYA) for Equipment Innovation for the Portable, Continuous, Miniature and Modular (PCMM) manufacturing platform, now operational at Pfizer’s facility in Groton (Connecticut USA). With the award-winning PCMM concept, GEA and its partners are leading the way toward smaller, more flexible, continuous processing technologies that have the potential to transform the future of pharmaceutical development and manufacturing, and deliver customized quantities of drugs to patients in need in a quick and efficient way. This first-of-a-kind manufacturing system accelerates the speed at which tablets are produced. By miniaturizing the equipment, the continuous process can be enclosed in a portable, modular facility, which can be shipped to any location in the world and quickly assembled. Once up and running, the system will deliver the capability to transform powders into uncoated tablets in minutes, which can take days or weeks with current technology.

At the heart of both PCMM and GEA’s continuous solution is ConsiGma™, a multipurpose platform that has been designed to transfer powder into coated tablets in development, pilot, clinical and production volumes in a single compact unit. The system can perform dosing and mixing of raw materials, wet or dry granulation, drying, tableting and quality control, all in one line. By producing granules continuously, batch sizes are determined by how long users run the machine; and, because of ConsiGma’s innovative design, the amount of waste produced during start-up and shutdown is significantly reduced compared with conventional methods.

Able to process batches from 500 g to many tons, GEA has already tested more than 100 formulations for more than 150 customers at their process development centers in Europe, the US and Japan. Companies wishing to test their own product or run trials on ConsiGma™ equipment are invited to get in touch and discover the benefits of continuous manufacturing for themselves. Don’t miss the laboratory scale ConsiGma™ 1 in action at POWTECH 2016 in Nuremberg; GEA will be running real-time trials throughout the show.

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