From single units to fully integrated lines, ConsiGma® 4.0 is the modular approach to #GoingConti

If the recent coronavirus pandemic has taught the global pharmaceutical manufacturing industry anything, it’s that collaboration and co-operation are the very cornerstones of expedited drug development and, perhaps, the fundamental principles that both innovator and generic drug producers should adopt in the future — and present — as they bring new therapeutics to market in a safe and efficient way.

Committed to “engineering for a better world,” GEA is wholeheartedly embracing this concept as it expands, integrates and consolidates its ConsiGma® portfolio of continuous oral solid dosage granulation, drying and tablet compression equipment. 

Based on three key pillars, the multipurpose ConsiGma® 4.0 platform — designed to transfer powder into coated tablets in development, pilot, clinical and production volumes — can now be supplied as 

  • a fully integrated line  
  • standalone plant for dedicated “bin-to-bin” unit operations  
  • a combination of modules that can be installed in both new and existing facilities with selected and qualified third-party machinery.        

GEA can provide top-of-the-range, fully configurable manufacturing systems that convert powder into coated tablets in a single line, as well as customer-specific equipment that can be integrated with existing plant. Irrespective of the size or scale of your CM implementation strategy, GEA’s SCADA-compliant ConsiGma® “Conductor 4.0” control software facilitates the integration and consolidation of independent unit operations. 

In the post-COVID world, GEA has taken a major step to make its cutting-edge continuous manufacturing equipment available to all. By taking a more holistic and inclusive stance as a trusted supplier to the pharmaceutical industry, the company can now deliver an unparalleled combination of highly effective, flexible and cost-efficient production solutions to a wider and more diverse array of companies.

ConsiGma® 4.0 = Industry 4.0

The pharma manufacturing landscape is evolving as never before. Much of this change is being driven by greater connectivity and Industry 4.0 — the fourth industrial revolution. Continuous manufacturing and is an enabler of both digitalization and the industrial Internet of Things (IIoT). ConsiGma® 4.0 makes it possible to gather and analyze real-time data, speed up production processes faster and run more efficient manufacturing lines that deliver higher-quality goods at a reduced cost. 

GEA has already invested considerable time and resources to develop state-of-the-art augmented and virtual reality (VR) applications, and now offers a comprehensive suite of Remote Support tools for planning, testing, installation and service, as well as training, modeling platforms and digital twins. 

ConsiGma® 4.0 will help you to optimize your quality assurance procedures, offer higher levels of process transparency and tighter control of your entire supply chain, resulting in improved productivity, increased Overall Equipment Effectiveness (OEE) and enhanced real-time planning and scheduling. 

With advanced analytical tools and our ConsiGma® 4.0 R&D product line, QbD principles can be applied all the way from early stage product development through to commercial-scale manufacturing, enabling significant time savings and faster process transfers. Plus, GEA’s centers of excellence, such as the GEA Pharma Solids Center in Wommelgem, Belgium, provide access to a full range of test facilities and teams of experts who can help with product and process development using both batch and continuous technologies.

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. ConsiGma® 4.0 is the next step in that journey.

For further information about GEA’s processes, products and solutions, contact gea.com/contact or visit our Facebook page @GEAPharma

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