Continuous Manufacturing
Technology
Continuous Manufacturing to believe in.
Continuous Manufacturing underpins the improvement of pharmaceutical products in terms of potency, effectiveness and safety by means of accurate process control. IMA Active is now ready for the paradigm shift in pharmaceutical manufacturing and taking the lead in the future of pharmaceutical technologies for OSD forms. IMA Active’s belief in and knowledge of Continuous Manufacturing have grown stronger thanks to intensive R&D work carried out on two fronts.
Continuous flow of benefits.
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Benefits
Quality
• QbD approach bringing reduced time for quality control and test release.
• Reduced risk of human errors due to a high level of automation. -
Benefits
Flexibility
• Batch size and production volumes are defined by runtime. No more constraints due to equipment size.
• Flexibility in process flow thanks to modularity of the Continuous Pharmaceutical Manufacturing operations.
• CM unit operations are compact, designed with standard connections and minimum utilities, conceived for easy and quick installation to replicate in any manufacturing site worldwide with a short start-up time. -
Benefits
Sustainability
• Reduced plant footprint which means smaller equipment, no more need of work-in-process inventory, fewer personnel, with consequent space and energy savings.
• Lower environmental impact through reduced utility consumption.
• Reduced process surface to clean: less water consumption.
• Less risk of drug shortage thanks to reduced time to market. -
Benefits
Costs
• Important contribution for reducing costs includes smaller equipment and fewer manufacturing steps, with consequent savings for installation, validation and maintenance. In addition, rapid development, improved yields and fewer personnel achieve overall estimated cost reduction, ranging from 30% to 50%, with impact on drug affordability as well.
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Benefits
Safety
• Patient safety is ensured by adoption of QbD and PAT (Process Analytical Technologies).
• Minimum risk to fall OOS (Out of Specification).
• Operator safety provided by lower risk of exposure means reduction of PPE.
• Operators are better protected since product handling, process space and air displacement are significantly reduced. -
Benefits
Efficiency
• Shorter time to market due to quicker product and process development, minimisation of process scale-up.
• Significant increase in productivity and improvement of OEE generated by:
– Faster production time, also by minimising product handling.
– Reduction of waste and losses.
– Quicker changeover due to minimum downtime.
The continuous scenario.
Based on more than 50 years’ process experience, IMA Active would like to involve you and rapidly illustrate the benefits of continuous processing. IMA Active contributes to making Continuous Manufacturing available for all and not just for a small elite of pharmaceutical manufacturers.
