ConsiGma™ CDC ConsiGma™ Continuous Direct Compression

A Complete tablet production facility with embedded quality control in one machine, integrating four key GEA technologies - accurate loss-in-weight feeding, continuous blending, GEA compression technology and online measurement of CQAs (Critical Quality Attributes) with Lighthouse Probe™.

The ConsiGma™ CDC for direct compression is the latest expansion of GEA's continuous portfolio for cost effective, compact, high yield manufacturing systems. It offers a robust and flexible manufacturing method for a wide range of products.

Low-cost, high-yield pharmaceutical manufacturing of oral solid dosages

ConsiGma™ CDC integrates 4 key GEA technologies - accurate loss-in-weight feeding, continuous blending, GEA compression technology and online measurement of CQAs (Critical Quality Attributes) with Lighthouse Probe™ - all in a small footprint machine. The closed coupling of feeding, blending and compression eliminates concerns on segregation. 

The GEA “Loss in weight” powder feeder technology enables a level of accuracy never achieved before in the continuous feeding of the powders for tablets. It has been tailored for the needs of the pharmaceutical industry with a small footprint and fast exchangeable feeding modules. 

The CDC can contain six feeders to feed each excipient separately. The control system automatically runs the recipe and makes sure that the correct dosage is applied at all time.

The GEA blender set-up consists of 2 blending units - one low-, and one high- shear unit, which make sure that excipients are mixed homogeneously, and delivered directly to the tablet press without any risk of segregation. The residence time is carefully controlled, and there are minimal start-up and shut-down losses.

The LightHouse Probe™ NIR sensor monitors the blend uniformity in the material flow directly above the tablet press feed section.

The GEA compression technology, with air compensator for extended and controlled dwell time, guarantees optimal tablet quality.

The ConsiGma™ for direct compression technology (patent pending) can be tested at our global competence centre near Antwerp, Belgium. Apart from the direct compression line, the test centre also allows testing of continuous wet granulation and drying at both R&D and full-production scale, including tableting and coating. 

 

Features

  • Compact, all-in-one, tablet production line for direct compression formulations.
  • Combines all of the manufacturing steps between dispensing and compression into a single GMP system.
  • Proven blending technology with minimized start-up and shut down losses and inline monitoring of Critical Quality Attributes.
  • Reduces GMP space by more than 50%, lowering costs due to compact system layout. 
  • modular system enables containment and fast changeovers using wash-off-line cleaning
  • Embedded QMS reduces quality costs and increases security of outcome
  • Integrated feeding, blending and compression system prevents segregation
  • Reduced work in process, reduced space requirements, reduced costs.

Compliant Manufacturing

The system complies with the latest guidelines on QbD (ICH Q8, Q9, Q10). In addition, its reduced footprint and compact design decrease GMP space requirements and costs; there’s no need for scale-up studies and, with rapid changeover times and efficient offline washing, downtime and wash water costs are also reduced. Built with Quality by Design in mind, our design quality goes in, your quality product comes out.