Continuous Reactor to Handle Solids in flow: Developed for fast, exothermic reactions, the geometry of this reactor enables solid particulates to be processed in flow.
Membrane Separator By-Pass:Separates aqueous and organic streams without headspace, including difficult emulsions. The system automatically detects when membrane fouling occurs, responding by bypassing the compromised membrane to a fresh separation unit in addition to cleaning the fouled membrane. Upon completion of cleaning, the system reverts back to the first membrane separation unit.
Mixed-Suspension, Mixed-Product Removal (MSMPR) Crystallization: The most simple and general system to perform crystallizations, a multi-stage MSMPR crystallizer is typically utilized to convert batch crystallizations to continuous.
Heterogeneous Crystallization: API in different solutions can be crystallized on crystalline or polymeric excipients to eliminate downstream processes such as granulation.
Integrated Nucleator and Tubular Crystallizer: A supersaturated solution is run into a nucleator device containing a specific seed initiating the nucleation process. Particles are then transferred into a tubular (plug flow) crystallizer where growth occurs.
A Continuous Rotary Filter purifies the crystallization slurry, removing unwanted impurities from the Active Pharmaceutical Ingredient (API) or intermediate product. The slurry is deposited on a rotating porous plate, where the mother liquor is filtered out through a high vacuum system. The thin (~1 mm) wet-cake is effectively and efficiently purged of impurities through the application of multiple wash stations, after which it is transported to the next unit. A built-in Clean-In-Place mechanism restores the filter plate, while the purified wet-cake is analyzed with in-line PATs for real-time purity and concentration. The system has the ability to segregate filtrate streams, enhancing solvent recovery.
A Continuous Drum Dryer converts concentrated or diluted suspensions containing the API into a dry, flowable powder. The suspension is deposited onto two heated rotating drums, forming thin layers that are quickly dried. Concurrently, a specified load is applied between the two drums, reducing particle size to the desired specification. The entire system is under vacuum, allowing the process material to be maintained at lower temperatures. The dried API is then conveyed through a cyclonic separator, before it is sent to the next unit operation. In-line PATs allow for real-time measurement of particle size, residual solvent and crystal form.
Extrusion Molding Coating (EMC): An Integrated Extrusion-Molding-Coating process produces pharmaceutical-grade coated tablets in a continuous fashion. The API and required excipients are fed into the unit, where they are heated and mixed, resulting in a uniform melt, or extrudate. Coated tablets are then produced as this process material is molded and coated in subsequent sections of the unit. In-line PATs allow for real-time measurement of content uniformity and crystal form. The entire system operates solvent-free.
Thin Film/Electrospinning: A process for manufacturing solid oral dosage forms directly from solutions of purified API. A solution is processed either through thin-film casting or electroprocessing to produce a thin layer of an API/excipient matrix. The film is subsequently engineered to form tablets of consistent physical dimensions (e.g. thickness, diameter and mass). All steps are continuous and run in an integrated manner.