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Continuous Processing Technologies for Intermediate Manufacturing


Sam Tadayon, Ph.D. (Executive Director, Process Engineering, STA Pharmaceutical)

Location: 119B

Date: Tuesday, April 24

Time: 11:45am - 12:30pm

Pass Type: Conference Pass, VIP Attendee - Get your pass now!

Track: Drug Manufacturing

Vault Recording: TBD

Continuous processing is becoming more widely recognized in the pharmaceutical industry as the number of scientists with expertise in the technique is increasing, and the need in the pharmaceutical field for methods with safer, faster and more sustainable process with higher quality and lower costs is growing.

Through case studies, Dr. Tadayon compares the advantages of continuous processing to the traditional batch process methods. Continuous processing uses smaller volumes than batch, conferring several benefits including the ability to fully control parameters during the course of a reaction such as control of residence time for more precision, and the use of custom microreactors with low maintenance and operational costs for multi-phase systems. Safety and sustainability advantages will be highlighted such as greater control for unstable reactions, and the sustainability of using less solvent quantities some of which may be costly, toxic or environmentally harmful.

Cost incentives including reduction in energy costs, solvents, impurities and waste as well as the possibility for time savings with shorter synthetic routes with less break time between consecutive steps as another major driver for the pharmaceutical industry to adopt the new technology. Starting a manufacturing process with continuous steps in the early stages of drug development yields the greatest benefits in terms of time and cost due to easier scale up and scale out as the drug advances towards the commercial launch compared to batch methods.

5 Key Session Takeaways:

Continuous processing can resolve manufacturing issues arising from today’s more complex therapies:

  • Safety – Reactions that require extreme conditions or toxic solvents
  • Sustainability – Lower use of solvents for less environmental waste
  • Complex multi-phase reactions – Fewer solvents and purer material
  • Easier scale-up as compound moves towards launch
  • Cost saving in operation – Lowers operations and raw material costs