In-Line Process Analytical Technology (PAT)
Real-time insight for unmatched control
At the heart of CONTINUUS’s Integrated Continuous Manufacturing (ICM) lies advanced process analytical technology (PAT). By embedding real-time sensors, analytical instrumentation, and an integrated control system throughout the continuous line, PAT transforms data into actionable control. This ensures that material consistently meets critical quality attributes and dramatically reduces off-spec production.
A Closer Look at PAT
CONTINUUS integrates PAT instruments, such as Raman spectroscopy, near-infrared (NIR), focused beam reflectance measurement (FBRM), in-line XRPD, and infrared (IR), directly into reactors, crystallizers, filters, dryers, and tableting systems. These tools monitor critical process parameters such as concentration, crystal size, polymorph form, moisture content, and content uniformity in real-time. Data streams feed into Emerson’s DeltaV closed-loop control systems, instantly adjusting temperatures, flow rates, or pressures to maintain optimal process conditions and prevent deviations before they occur.
Key Features of CONTINUUS’s Process Analytical Technology (PAT)
In-Line Process Analytical Technologies
Offline Benchtop Analytical Technologies
In-line PAT facilitates robust closed-loop control by tracking processes in real-time, including quantifying reaction progress and impurities, particle size and chord length distribution, composition and moisture, solution state, temperature, flow rate, and pressure.
Instruments Utilized
- Mettler Toledo ReactIR
- Mettler Toledo Focused Beam Reflectance Measurement (FBRM)
- Mettler Toledo ReactRaman
- Kaiser Raman
- Bruker NIR
- Malvern Insitec particle sizer
- UV-Vis
- pH, conductivity meters
- Density
- Hard sensors (temperature, flow, pressure)
Offline analytics verify identity and purity of compounds, detect residual solvents, determine particle size, polymorph, and crystallinity, measure water content, mass, and solvent loss, and assess product stability.
Instruments Utilized
- HPLC, UPLC, LC-MS
- Preparative HPLC
- GC with headspace sampling
- Laser-based particle sizing
- XRPD
- Karl Fischer titration
- Dissolution UV-Vis
- TGA
- DSC
Advanced Manufacturing Expertise to Guide Process Analytical Technologies
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.