Continuous Formulation & Drug Product Development
From API to finished dosage form in minutes
CONTINUUS’s extrusion injection molding system revolutionizes oral solid dosage (OSD) manufacturing by compressing what is traditionally a multi-step, time-consuming tablet production process into a single, solvent-free operation. This integrated technology combines hot melt extrusion with precision injection molding to produce tablets in as little as 10 minutes, from dry API powder to finished dose. Designed for speed, versatility, and quality, the system supports a wide range of dosage strengths, release profiles, and API forms.
Additionally, we have designed, but not yet reduced to practice, an Integrated Continuous Manufacturing (ICM) process for the highly efficient manufacturing of sterile injectables.
A Closer Look at Continuous Final Dosage Form Manufacturing
For solid dose manufacturing, CONTINUUS has developed an extrusion injection molding process to streamline tablet production into one seamless step, enabling real-time control and unmatched flexibility in formulation design. Whether the goal is to preserve crystallinity or promote amorphization for enhanced bioavailability, this continuous process supports immediate-, modified-, and controlled-release applications. With in-line PAT tools measuring content uniformity and crystal form, manufacturers can ensure consistent product quality with every run. Because the system is solvent-free, it simplifies handling and supports sustainability goals.
Key Features of CONTINUUS’s Tableting Technology
- Immediate-release tablets
- Controlled-release and modified-release tablets
- Crystalline or amorphous solid dispersions
- Low and high dosage strengths
- Custom-shaped products with embossing or break lines
- Solvent-free process
- In-line PAT for product uniformity
Modes of Operation
- Feed of API and excipient blend
- Mixing and extrusion of tablets
- Direct transfer to injection molding
- Molding of tablets
- Inline PAT reading
- Tablets out
Advanced Manufacturing Expertise to Guide Continuous Tableting Process Development & Integration
We offer comprehensive process development and integration services for all continuous manufacturing unit operations.
Integrated Continuous Manufacturing
/ API
- Flow Chemistry Reaction
- Polish Filtration
- Crystallization
- Solvent Recovery
- Filtration
- Drying
Unit OP Multi-Step
- Extrusion
- Injection Molding
- Coating
Plug-and-Play Unit Operations & Supporting Technologies
CONTINUUS’s modular, plug-and-play unit operations are engineered for seamless integration and rapid configuration and re-configuration. These units can operate as part of an ICM line or be implemented individually, enabling flexible deployment tailored to each program’s needs.
Join the CONTINUUS Revolution
Learn how Integrated Continuous Manufacturing will transform your supply chain by reducing the cost of goods, increasing product quality, enhancing sustainability, and accelerating your path to market.