Continuous manufacturing for higher productivity in the pharmaceutical industry
Decreased fluctuations in production, higher yields, and more profitable processes with lower costs for operation, equipment, and investment are the key factors for greater competitiveness in the pharmaceutical industry. One of the most critical points is continuous utilization of production capacity.
Many pharmaceutical manufacturers are already converting their processes to adopt continuous production. What this means is that active ingredients are produced in compact, closed units, with a higher degree of automation and fewer manual interventions. For this purpose, the production steps that are performed sequentially in a classic batch process are integrated in a continuous process. Siemens’ solutions and what is arguably the industry’s most cutting-edge Process Analytical Technology (PAT) software, SIMATIC SIPAT, enable pharmaceutical manufacturers to increase system utilization by a third and to lower their production costs by 10% to 20% after only a short time.
Moving toward continuous production with SIMATIC SIPAT
The technological basis for continuous manufacturing is the use of Process Analytical Technology (PAT). Previously, it was virtually impossible to determine the clinical efficacy of an active ingredient online. This made the control and optimization of processes more difficult, as laboratory tests usually take a long time. PAT closes this information gap. Data are collected directly in the process. Tools for analysis improve the manufacturers understanding and control of the process, increase process quality, and reduce the risk of losing products due to nonconformity. Integrated options for process optimization and quality controls ensure the correct quality straightway Right First Time quality.
Based on PAT, continuous production literally makes classic batch processes look outdated: the utilization of assets increases by 30% to 40%, and a product that previously took one or even two months in production is finished after two days. Continuous manufacturing can become a reality for you too with our SIMATIC SIPAT solution.
Continuous production pays off
When pharmaceutical companies introduce continuous manufacturing in their production processes, they can simultaneously address several key issues that increase system capacity and optimize their processes in almost all areas. These issues include the following:
Verification of product quality and the real-time release of products
Lower investment and operating costs, higher energy efficiency, and lower CO
Shorter time to market and greater flexibility in production across the entire product lifecycle
Use our expertise and our broad portfolio of aligned systems and solutions for continuous manufacturing. In collaboration with you, we will determine how you can best benefit from continuous production. We will assist you with integrated data-supported process automation and help you with the implementation to ensure that your system complies with all relevant regulations and guidelines.
The systems for continuous manufacturing that we have developed in close collaboration with several pharmaceutical companies and OEMs show that continuous manufacturing has enormous potential to enable companies to release products in real time.