Continuous Process Excellence
Smart manufacturing with innovative flow chemistry
In an effort to move away from conventional batch production and modernizing the global chemical processing industry,
continuous manufacturing (CM) is the common vision and desire with the potential to increase efficiency, quality and
flexibility in manufacturing.
Dec is a leading company in the industry, providing comprehensive solutions for the entire manufacturing process. We handle everything from receiving raw materials to synthesizing APIs and processing compounded drugs into final dosage forms, including injectables. Our expertise spans from bench-scale development to large-scale production, making us one of the few companies capable of offering end-to-end CM process solutions.
Experts in ‘end to end’ continuous processing we provide
-
Modules from grams per hour to 100kg per hour
-
Unique continuous Advanced Configurable Process Plant ACPP design
New concept for decentralized, flexible continuous manufacturing​​​​
Continuous Reaction & Crystallization
Available in a range of sizes to suit your requirements from laboratory to production scale
Crystallizers
Ideal for cooling, evaporative and antisolvent crystallisations
Low shear mixing produces little particle attrition with good control over particle size distribution and morphology
Flexible modes of operation – batch, semi- or fully continuous
Reactors
Fully automated from single vessel batch or continuous stirred tank reactors to multi-vessel continuous or semi-continuous chained stirred tank reactors. Liquid/Liquid, Solid/Liquid and Gas/Liquid capabilities at pressures up to 25 bar and temperatures up to 200 °C. Improved residence time distribution compared to traditional stirred tanks.
Key Features
​
-
Unique chemistry facilitators for gas to liquid hydrogenency
-
Liquid liquid, gas liquid and solid liquid reactions and crystallisations acting as a catalyst for crystallisation
-
Highly efficient heat transfer and mixing capabilities
-
Excellent crystal size and morphology control
Equipment can be provided with temperature controlled transfer lines to avoid unwanted crystallisations or side reactions. Probe adapters available to suit most PAT
Continuous Filtration & Drying
Continuous filtration is available in evaluation, pilot, production scale platforms
Lower footprint - One complete plant replaces a traditional 2 to 3 floor batch production facility.
Astro DecFilterDryer – a game-changing filtration solution available for both pilot and production scale operations
-
High Capacity: Process up to 100 kg per hour, with an impressive capability of 750,000 kg per year (operating 300 days at 24 hours)
-
Proven Technology: Utilizes well-established Nutsche Filtration for reliable performance​
-
Efficiency Boost: Processes thin cakes to significantly reduce filtration time and allows for efficient washing, minimizing solvent usage​
-
Automation Ready: Features automated WIP/SIP management​
-
Zero Product Loss: The innovative inverted discharge method ensures no product heel, maximizing yield​
-
Swift Changeovers: Experience faster product changeovers to keep your production line agile​
-
Flexible Integration: Can easily interface with both batch and continuous systems​
-
Safety First: Available in both Non-ATEX and ATEX versions to meet diverse operational needs​
-
Compact Solution: Also offers a single-stage version for smaller operations at 10kg per hour
Modern flow chemistry technology for enhanced efficiency in Fine Chemical, Pharmaceutical and Laboratory processing
Filter dryer systems automatically filter, wash, dry and discharge solids in a continuous manner.
Protocols
​
-
No mechanical agitation damage or crystal shear
-
Reliable consistency in cake filtration
-
Accurate repeatability of washing parameters
-
Atomization nozzles dispense wash solvent preventing disturbance to the cake
-
Thinner cake height technology, typically 10 - 30 mm
-
Improved wash efficiency!
-
Local HMI or DCS control system allows for safe operation
-
Integrated alarm systems for automated continuous operation
Key Features
​
-
Very high repeatability and consistency in filtration
-
Reduced solvent usage, energy and waste
-
0.1 mm heel! Significantly lower heel – Significantly reducing product loss!
-
Entry to exit cycle time in minutes… not hours!
-
Filtration, washing and drying in just a few short runs!
-
Drying to <1% moisture content achieved within minutes
-
Typical throughputs of 1 kg per hour to 24 kg per hour of dried product
Drying validated with drying kinetics models
Scalable Continuous Processing Solutions
Lab
Pilot
Production
Inclusive Solutions from the Raw Materials to the End Product
