Continuous processing in pharmaceutical manufacturing

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There may be upwards of six or seven steps in the process that are completed within six or seven pieces of equipment before a product is complete.

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Continuous pharmaceutical manufacturing sees a drug taken from its base ingredients to the final product with no need to stop during production. This means there is no need to shut down equipment and no down time as the product is created.

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Essentially, batch processing must stop from step to step throughout creation while the continuous process creates a product with no need to stop until the product is complete. Both processes provide pros and cons to the manufacturer, and either one is a perfectly sound way to produce a great final product, depending on your needs.

Thermo Fisher Scientific continuous manufacturing services include:

A good visual of this process can be seen here. Perhaps the most definite advantage of batch production is that the set-up costs are initially less expensive.

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Also, each batch is more easily tailored to be unique. Lastly, there are certain products and materials that require batch manufacturing due to their composition or formula. Using batch production, drug companies can produce specific amounts of a certain product and then adjust their manufacturing priorities according to the changing demands of the market.

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Continuous manufacturing can be a potential solution to that problem. Continuous pharmaceutical manufacturing is more time-efficient, reduces energy needs, helps to increase productivity and reduces the amount of overall waste. The risk of human error is also reduced because continuous processing means fewer people are involved in the production process from start to finish.

Outpace competition with real-time product release

Many have inquired about issues that may arise in the case of a recall using the continuous manufacturing method, but worries can be quickly put aside by using lot numbers. No matter what kind of manufacturing process you require, General Kinematics is here for you. Contact one of our expert representatives today. Click here to cancel reply. Name required. Email will not be published required.

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Solid materials handling is an important part of many industrial processes. However, if not properly managed, solids handling operations can quickly become system bottlenecks that significantly reduce process efficiency and system throughput. This article highlights some critical issues regarding the flow of solid materials as well as an overview of some material flow systems. This allows materials to be processed in an uninterrupted stream.

Our modular design, nonstop, fully integrated process is not restricted to batch size and offers a range of advantages, including:. Step-wise batch processing is reliable but wastes valuable time and resources.

Keeping up with continuous processes for OSD

Batch processing also runs the risk of introducing contamination and mistakes when product is held up between steps. Continuous manufacturing can overcome these issues. The Thermo Fisher approach to continuous manufacturing brings quality control to the next level.


Starting materials are fed into the process train, the materials flow through one or more operations, and the final product is collected at the line end. Technicians continuously monitor the process. The team can use information from one operation to adjust other operations before or after it in the same stream. As the FDA and other global regulators increasingly prefer the use of continuous manufacturing as a more reliable and safer drug manufacturing technique, you can benefit by outsourcing your project to the industry leader in continuous manufacturing.

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Speak with our continuous manufacturing experts to see if this solution is a fit for your project. Learn more about our Greenville, NC facility, which features our first operational continuous manufacturing line. Continuous Manufacturing.

26 Feb, 2018

Continuous manufacturing: Offering flexibility and greater process control Historically, drug products have been made in a batch process where API and excipient materials are added in discrete steps in predetermined amounts and processed in discrete phases usually on separated equipment trains. Our modular design, nonstop, fully integrated process is not restricted to batch size and offers a range of advantages, including: Maximum flexibility to meet unique client product and capacity needs Real-time monitoring and adjustment to maximize process control Greater control over process validation to lower costs of product development and minimize batch rejection Smaller facility footprint compared to conventional batch processing equipment Step-wise batch processing is reliable but wastes valuable time and resources. admin