Advanced Control System
Orchestrating every step of continuous manufacturing
Advanced control systems serve as the digital backbone of CONTINUUS’s Integrated Continuous Manufacturing (ICM) systems, coordinating reactors, crystallizers, filters, dryers, and tablet injection molders in real time. By uniting process analytics, automation, and feedback loops/feedforward control, our control architecture ensures seamless operation, optimal performance, and reliable product quality from the pilot plant through commercial production.
A Closer Look at Advanced Continuous Manufacturing Control Systems
CONTINUUS leverages a modular, skid-mounted control framework that utilizes Emerson’s DeltaV, an industry-leading distributed control system (DCS) technology, paired with custom logic for continuous operations. All unit operations feed data from embedded PAT sensors into a central control network where closed-loop algorithms continuously adjust flow rates, temperatures, pressures, and agitation speeds to maintain defined set points and design-space boundaries. Integrated alarm management, recipe control, and electronic batch records deliver full traceability, secure audit trails, and facilitate rapid troubleshooting across the ICM line.
Key Features of CONTINUUS’s Advanced Control System
- Real-time process monitoring
- Model-predictive control (MPC)
- Closed-loop feedback control
- End-to-end integration
- Digital twin/simulation capability
- Compliance and data integrity
- Alarms and predictive maintenance
Modes of Operation
- Manual model
- Automatic model
- Cascade model
- Remote mode/supervisory model
- Emergency mode/safe mode
- Simulation mode
Advanced Manufacturing Expertise to Guide Advanced Control Systems
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.