Continuous Manufacturing Workshop 2025

For two days, everything at L.B. Bohle centred on the continuous production of tablets, one of the key topics in the pharmaceutical industry. At the "Continuous Pharmaceutical OSD Production" workshop, 50 experts from the industry came together to discuss the latest developments and practical experience in the continuous production of solid dosage forms. In live demonstrations, the participants experienced QbCon® technology and other key technologies in action. continuous Manufacturing thus became a tangible experience.

After the welcoming address by Tim Remmert (Managing Director), Burkhard Schmidt (Head of Sales), Dr Robin Meier (Head of Science and Process Engineering) and Alexander Seibel (Business Development Manager Continuous Manufacturing), the programme began with exciting keynotes.

Erin Dippold from Merck & Co. in the USA gave extensive insights into the selection and development of new production processes. She praised the uncomplicated Scale-up, the very fast results achieved in development and the low material consumption of the QbCon^® 1 continuous pelletiser and dryer. "Merck & Co. has been working on the introduction of continuous twin-screw pelletising for a very long time," explained Alexander Seibel. Initial tests and analyses were started back in 2011. "After the desired solution had not been found by 2019, the first tests were carried out on QbCon^® 1," continues Seibel. Several series of tests and scale-up trials on the QbCon^® 25 system led to the order of two QbCon^® 1 systems in 2023. The first system was built in the OEB 3 containment version. For this purpose, the standard system was extended with a number of additions to increase the dust-tightness of the system, which is used in Research & Development.

The second machine was built for even higher dust-tightness requirements (OEB 4). This machine is used in clinical sample production and has a higher degree of automation.

Practical experience - insights into real CM projects

In the second keynote speech, Raphael Wiedey from Merck KGaA provided extensive insights into the installation of the QbCon^® 1 system, which realises the process from powder to coated tablet. After Merck KGaA had initially focussed on a competitor from
L.B. Bohle, the company changed its decision and extensively tested the L.B. Bohle technology for continuous production. the order was placed in 2021 and the Factory Acceptance Test (FAT) for the very extensive system took place in Ennigerloh in 2022. "The complete system with extensive PAT (Process Analytical Technology) equipment consists of a QbCon^® 1 for Continuous Wet Granulation and drying and a mixing and dosing unit, each of which is completely enclosed by an isolator. Other components of the system include a Sieving unit from the BTS 100 series, the XL 100 WipCon^® Tableting unit and the semi-continuous KOCO^® 25 coater. The system is fed by two automated HS 400 Lifting Columns," reports Dr Robin Meier. In addition to the main components, the control system for the entire plant was also supplied by L.B. Bohle. "The challenge with this system was to integrate components from different suppliers. Gericke AG, Franz Ziel GmbH and KORSCH AG are all involved in the project," continues Dr Meier.

Technology you can touch: Practical demonstrations impart knowledge

On the afternoon of the first day, after the theory, the participants experienced the systems in action: during a live demonstration of the QbCon^® 1 system, the experts were able to see the benefits in practice for themselves. Easy handling, fast results and low material consumption are just some of the advantages of the system.

At the same time, continuous production from powder to coated tablets using Dry Granulation was demonstrated in the Technology Centre. With a focus on the BRC Dry Granulator and the semi-continuous Coater KOCO^®, participants learned first-hand how production can be fully automated and realised in a true continuous process.

"The practice-oriented sessions were particularly conducive to intensive dialogue," says Burkhard Schmidt, looking back on the demonstrations. "The numerous questions from the participants showed their interest and, above all, their expertise. Many companies are working intensively on the introduction of Continuous Manufacturing, and the workshop definitely confirmed this," reports Schmidt.

Practice and excursion to Plant 3

The second day of the workshop focussed on a comparison between traditional batch processes and the modern bin-to-bin process. In practice, the QbCon® 25 Twin-Screw Granulator and continuous dryer were compared with the VMA Single-Pot Granulator. As a further highlight, the participants familiarised themselves with the final months of the process machines in Plant 3. In addition to several BFC Tablet Coaters of the latest series, a KOCO^® in combination with the fully automated ROB 50 tablet container handling system and the VMA 1200 Single-Pot Granulator were inspected.

After two intensive days full of insights, discussions and live demonstrations, L.B. Bohle agreed that the workshop was a complete success. "The response was overwhelming. Our goal was to make Continuous Manufacturing tangible. We succeeded and put our technologies on show," says Tim Remmert, drawing a very positive conclusion.