Continuous manufacturing without compromise.
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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
01
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‑engineering03
Exceptional process flexibility
Fast changeovers and short cleaning cycles reduce downtime Multiple configurations enable adaptation to different products, batch sizes, and throughputs02
Consistent quality with modern controls
Continuous operation with real‑time monitoring improves consistency Supports robust process control aligned with ICH Q13 expectations04
Lower cost and smaller footprint
Fewer process steps and reduced material handling Compact layouts contribute to lower cost per tablet and improved sustainabilityMore 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.Powiązane produkty
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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.
Więcej niż maszyna: klucz do poprawy wydajności zakładu
Wydajność maszyny nie przekłada się automatycznie na wydajność fabryki. Prawdziwa poprawa często zaczyna się od wyjścia poza ramy poszczególnych urządzeń i zrozumienia, w jaki sposób wzajemnie na siebie oddziałują procesy, systemy energetyczne i decyzje operacyjne. Jest to podejście kompleksowe, mające na celu odkrycie możliwości, które w przeciwnym razie mogłyby zostać przeoczone.
W jaki sposób zawór może wpływać na sposób produkcji żywności i napojów
Zazwyczaj w zakładach produkujących żywność i napoje zawory są uruchamiane za pomocą sprężonego powietrza. Tymczasem w GEA Hydract® Actuation Technology do sterowania zaworami wykorzystuje się wodę w zamkniętym obiegu sterowanym cyfrowo. W rezultacie otrzymujemy zawór, który można precyzyjnie utrzymać w odpowiednim położeniu i sterować nim z dużą dokładnością. Skutkuje to mniejszym zużyciem energii i większą kontrolą.
