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ConsiGma™

ConsiGma® Tablet Coating (TC) Modules

After compression, many tablet formulations need a coating to achieve the final product characteristics desired. To complete the ConsiGma™ tableting lines, GEA has developed a coater in line with its continuous manufacturing concept.

Enrobeuse ConsiGma

The ConsiGma™ coater is a high speed drum coater, sized and designed to be part of our integrated tableting solution. It can apply decorative and functional coatings using both aqueous and solvent based coating suspensions. The number of drums can be adapted to meet the actual throughput of the line (kg/h). It can also be executed with features which enable wash-off-line (WOL) for extremely fast change-over.

Concept

The ConsiGma™ coater is a revolutionary, new, high performance tablet coating technology that accurately deposits controlled amounts of coating materials on tablets – even if they are hygroscopic or friable. Designed specifically to be an integral part of the ConsiGma™ continuous high shear granulation, tableting and drying system, this groundbreaking machine is able to coat small quantities of tablets at very high rates, offering improved heat and mass transfer and using much less coating material than traditional technologies. 

Presenting a paradigm shift in tablet coating, this new type of coater subjects tablets to a cascading tablet movement that enables greater fluid application rates (higher coating build rates) than traditional coating pans. In addition, it is PAT compatible, efficient – warm up and drying times are faster than conventional coaters – and reliable, delivering a consistent, homogenous and even tablet weight gain and coating distribution. And, because the coater operates at higher speeds and temperatures than other products on the market, higher spray rates and improved tablet mixing can be achieved, expanding its application potential to polymer coatings and beyond what is currently possible. It can even be used to dedust tablet cores prior to coating. 

With more tablet movement within the coating barrel, the revolutionary design and the application of enhanced process conditions, the small-volume ConsiGma™ coater concentrates the tablet coating process, enabling faster throughput, time and cost savings, increased efficiency and a higher quality finished product, all of which are fundamental aspects of the drive towards continuous processing. 

Key characteristics

  • Plug flow / first-in-first-out principle: The same Consigma™ plug flow philosophy is implemented for the coating process . This allows for a comprehensive and reliable tracing of the product throughout the process.
  • Short process times of a few minutes. The complete coating cycle requires nominally 6-8 minutes for a 3kg tablet loading.
  • No scale-up. Same coating wheel is used in R&D and production
  • Gentle process. The combination of processing small quantities of tablets and the short process times makes the equipment suitable for coating very soft tablets. 

Produits connexes

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

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

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.

Lighthouse Probe™ - online measurement

Lighthouse Probe™ - online measurement

The Lighthouse Probe™ can be used for real-time monitoring of chemical and pharmaceutical processes and provides in-process window cleaning at any time, recalibration during the process, full CIP (cleaning) of wash housing and seal, and a clear view inside – even in difficult conditions.

NEP pour les usines de transformation pharmaceutique

NEP pour les usines de transformation pharmaceutique

L'optimisation du processus dépend de l'efficacité du nettoyage. Les systèmes de nettoyage en place (NEP) peuvent être incorporés dans tout l'équipement produit par GEA pour le secteur pharmaceutique, y compris les séchoirs à lit fluidisé, les granulateurs à haut cisaillement et les systèmes pour formules de dosage liquide. L'automatisation du processus de nettoyage garantit la reproductibilité, permet la validation et minimise les temps d'arrêt.

Procédé en continu pour la R&D pharmaceutique

Procédé en continu pour la R&D pharmaceutique

Lors des premières phases de recherche et développement de formules, la disponibilité des ingrédients actifs est souvent très limitée et il faut un équipement de procédé en mesure de ne produire que quelques centaines de grammes pour développer de nouvelles formules de médicaments. C’est pour répondre à ce besoin que GEA a développé ConsiGma™ 1, la version à l’échelle du laboratoire du concept ConsiGma™.

Wash-Off-Line pour les usines pharmaceutiques

Wash-Off-Line pour les usines pharmaceutiques

Outre les services de confinement complet, GEA offre des skids de lavage multifonctionnels qui peuvent être déplacés d'un emplacement à l'autre et utilisés pour nettoyer les différentes parties du procédé. Toutes les usines fournies par GEA comprennent un système NEP, DEP ou Wash-Off-Line (WOL) personnalisé, afin de répondre aux exigences de votre application.

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