Continuous Innovation: How GEA is Leading the Future of Pharmaceutical Manufacturing
From First to Leader
In 2004, GEA began a journey that would transform pharmaceutical manufacturing. By developing the first ConsiGma® continuous manufacturing (CM) system, we pioneered a new way to make oral solid dosage (OSD) medicines — faster, more consistent, and with better use of precious active ingredients.
Since then, we’ve built the largest installed base of CM systems worldwide. A vast portfolio of existing medicines has been transferred to continuous manufacturing, and many newly FDA-approved drugs have been developed using CM — the majority on GEA technology.
A Catalyst for Change
For years, the industry remained cautious about CM. But the need for speed, agility, and sustainability has only grown. Janet Woodcock of the US FDA put it simply:
Are you ready for the concept of continuous drug production? If not, get ready!
Janet Woodcock
US FDA
Building on Proven Foundations
GEA’s mission has always been clear: to help the pharmaceutical industry bring medicines to patients faster, more efficiently, and more sustainably. Over time, we’ve refined our ConsiGma® technology to make it simpler to run, easier to clean, and faster to change over — all while reducing API losses, energy use, and waste.
Innovation at GEA is never just about performance — it’s about engineering for a better world.
A New Step Forward: SimpleCT and CDC Flex
GEA never stands still. In collaboration with Hovione, we have continued to push the boundaries of what continuous manufacturing can achieve.
The ConsiGma® SimpleCT initiative focuses on making continuous tableting easier to adopt and operate, built on three principles
- Flexibility — adaptable technology for different products and scales
- Speed — faster development, deployment, and changeovers
- Simplicity — automation and smart interfaces for easier operation
And now, GEA proudly introduces the ConsiGma® CDC Flex (patent pending) — the next generation of continuous direct compression. CDC Flex offers:
- Dual-mode operation — continuous and batch on one platform
- Throughput range — 1 to 200 kg/h
- Standalone tablet press function — bypass feeding and blending when needed
- Customised blender configurations — low- or mid-throughput
- Simplified operation — faster product changeovers, reduced cleaning times, shorter delivery lead times
We believe that continuous tableting can offer significant benefits to our customers, not only by expediting time-to-market and reducing development and manufacturing costs but also by improving product quality and sustainability. Through our collaboration with GEA, we aim to revolutionise the continuous production of oral solid dosage forms, making the technology more accessible and efficient for pharma customers.
Filipe Gaspar
Vice President of Technology Intensification at Hovione
The Future is Continuous
From the first ConsiGma® line in 2004 to the launch of CDC Flex today, GEA has been at the forefront of pharmaceutical innovation. With SimpleCT and CDC Flex, we are once again redefining what’s possible — delivering solutions that are more flexible, more sustainable, and more ready for the future.
Continuous innovation is our commitment — to our customers, to the industry, and to a better world.
