Batch manufacturing is still commonplace in the pharmaceutical and chemical industry. Such operations require to use intermediate packaging for product storage between each process step leading to numerous disadvantages such as low production flexibility, process downtime, high risks of operator exposure, product contamination and sterility loss.

However, due to the very strict quality standards and complex validation processes, the pharmaceutical industry has faced difficulties to move towards the continuous manufacturing model. In spite of that, it is clear that with constant price pressure on pharmaceutical products this model needs to be adopted as soon as possible.

Since many years, Dec has been the front runner for linking processes without intermediate packaging/storing steps for both semi-continuous and continuous processing. From continuous reaction to continuous feeding of tablet presses, Dec has developed solutions to change from pure batch to continuous operation by designing flexible and multipurpose cGMP compliant facilities with adaptable containment levels.

Linking processes decreases batch failures due to a better control of the production with less human intervention. It minimizes downtime and energy consumption with fully automated CIP/SIP systems. Furthermore, the overall plant footprint will be reduced by decreasing the number of process steps.