While the major players in the CDMO space are seeing growth as business activities shift from 'global to local', this growth is realised not only by using expanded batch capacity, but also through the implementation of flexible continuous flow solutions. Prof. Tom Moody & colleagues at Almac Sciences suggest that for CDMOs 'The time is now to change & flow into the future!'.
The advantages of changing from batch to flow for primary processes are widely publicised to include increases in safety, process efficiency & product consistency; however, the drivers to change from ‘batch to flow’ vary & often depend on the sector, process type of interest & scale of operation. Examples include a speed to market, reduced cost of goods, efficient use of existing asset space & more recently supply chain security.
Continuous manufacturing not only fills the gap, when batch capacity is reached, but it also enables the performance of chemistries that would not be conventionally considered at scale, due to the low hold-up volume, small footprint & increased process safety. The modularity & flexibility of continuous flow set-ups enables the development of small, agile production plants that can be used for the manufacture of multiple products – facile re-configurations allow for rapid product change-over. Using a four-stage project workflow has enabled Almac Sciences to develop robust, safe & scalable processes from multi-kg to tonne-scale.
With the uptake of continuous manufacturing rising in the fine, specialty & pharma sectors, we see an increase in projects that are actively up-scaling from proof of concept towards manufacturing. For successful CM implementation, our view is that a multidisciplinary approach is required to achieve the project goals of safe, efficient, cost effective manufacturing & should involve a mixed Team from the outset, obtaining the much needed ‘departmental buy-in‘ & expertise (Read More).
This concept was discussed, in part, by Almac’s Prof. Tom Moody in Chemicals Knowledge Hub, ‘Successful Implementation of Continuous Flow Processes'.