ConsiGma® CDC Flex

Continuous manufacturing without compromise.

The ConsiGma® CDC Flex is a next‑generation continuous direct compression (CDC) platform that gives pharmaceutical manufacturers the freedom to move seamlessly from development to commercial production – faster, smarter, and with far greater flexibility than traditional batch processes.

Designed by GEA and Hovione, CDC Flex brings the advantages of continuous tableting within reach for companies with diverse pipelines, frequent changeovers, and evolving production needs.

Why consider ConsiGma® CDC Flex?

Pharmaceutical manufacturers face increasing pressure to shorten time to market, reduce costs, and respond faster to changing demand, without compromising quality or compliance. Traditional batch manufacturing often struggles to keep pace.

CDC Flex addresses these challenges by:

Enabling rapid scale‑up and scale‑out
Supporting small development batches and commercial volumes on one platform
Reducing process steps, footprint, and material handling
Delivering enhanced process control and consistent product quality

The result is a more agile, future‑proof approach to oral solid dosage manufacturing.

What is ConsiGma® CDC Flex?

CDC Flex is a highly flexible continuous direct compression system. Unlike conventional systems, CDC Flex is designed to operate in multiple configurations, allowing manufacturers to adapt the same unit to different products, batch sizes, and development stages.

From early R&D to commercial production, the same unit supports:

Direct compression starting from raw materials or pre blended products
Low and high throughput operation
Single or double-stage blending
Multiple configurations for blending and compression

All with intuitive controls and efficient, operator friendly design.

Designed for flexibility – built for reality

CDC Flex sets a new benchmark for flexibility in continuous manufacturing.

Thanks to interchangeable blender sizes within one unit, manufacturers can quickly adapt the system to new products or production targets – without redesigning the line.
This makes CDC Flex particularly attractive for:

Companies with wide product portfolios
Organizations transitioning from batch to continuous
Development teams seeking a clear path to commercial production

Throughput from 1 to 200 kg/h

R&D batches as small as 500 g

Single‑ or two‑stage blending

Immediate direct compression of pre‑blended products

Standalone tablet press function when needed

Key benefit of CDC Flex at a glance

Faster development and scale‑up

Seamless transition from formulation development to clinical and commercial production One platform supporting the full lifecycle, without process handovers or re‑engineering

Exceptional process flexibility

Fast changeovers and short cleaning cycles reduce downtime Multiple configurations enable adaptation to different products, batch sizes, and throughputs

Consistent quality with modern controls

Continuous operation with real‑time monitoring improves consistency Supports robust process control aligned with ICH Q13 expectations

Lower cost and smaller footprint

Fewer process steps and reduced material handling Compact layouts contribute to lower cost per tablet and improved sustainability

More than a machine: a collaborative platform

CDC Flex is the result of a long‑standing collaboration between GEA and Hovione, combining deep process knowledge with proven equipment design.

Together with SimpleCT, a suite of automated tools that enhance efficiency, containment, and operator safety during development, CDC Flex helps organizations adopt continuous tableting with confidence.

This partnership continues to evolve the platform, ensuring customers benefit from ongoing innovation and industry expertise.

See CDC Flex in action

Watch the video below to get an inside look at how the ConsiGma® CDC Flex works and how its flexible design supports both development and commercial manufacturing.

Related Products

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ConsiGma® SimpleCT is a set of automated development tools that make continuous tableting faster, easier and more accessible for pharmaceutical R&D.

ConsiGma® Direct Compression with Linear Blending (DC-LB) Lines

A highly integrated solution for continuous linear blending and direct compression, the ConsiGma® DC-LB lines offer all the advantages of continuous manufacturing: supply chain agility, small footprint, controlled blending and compression and improved quality.

ConsiGma® Granulation and Compression (GC) Lines

Highly integrated solutions for continuous wet granulation, drying and tablet compression, the ConsiGma® GC lines offer all the advantages of continuous manufacturing: supply chain agility, small footprint, controlled granulation and improved quality.

GEA Insights

The breakthrough that changed spray drying

In 1976, NIRO engineers responded to a competitive challenge by rethinking what spray drying could do. Their idea became the multi-stage dryer MSD. Fifty years later, the same fundamental principle helps turn liquids into the powders used in essential nutrition products and important medicines around the world. Refined through decades of engineering expertise, customer insight and continuous development, MSD is a story of innovation with lasting impact.

Beyond the machine: unlocking better plant performance

An efficient machine does not automatically make an efficient factory. Real improvement often starts by looking beyond individual equipment and understanding how processes, energy systems and operating decisions affect one another. It’s a holistic approach designed to uncover opportunities that might otherwise be missed.

How a valve reshapes the way food and drinks are made

In food and beverage plants, valves are commonly operated using compressed air. GEA Hydract® Actuation Technology moves valves with water instead, in a closed, digitally controlled circuit. The result is a valve that can be held exactly in place and steered in fine-tuned steps. This results in lower energy use and greater control.