Continuous production plant for the pharmaceutical industry
Continuous production line - QbCon®
The paradigm shift from batch production to Continuous Manufacturing requires a rethink of both the production processes used and the automation technology required.
More about the highlights
Due to comprehensive quality improvement initiatives - primarily driven by the FDA - continuous manufacturing for the production of solid pharmaceuticals is becoming increasingly important.
The ability to monitor a production process more closely using PAT and thus consistently manufacture high-quality products is at the centre of this initiative.
As a technology leader for machines and processes for pharmaceutical solids production, L.B. Bohle supplies comprehensive solutions for entry into continuous production or for optimising existing processes with a high development speed.
QbCon® realises the production of pharmaceuticals continuously from start to finish in an uninterrupted production flow. Production is realised as follows:
- Continuous dosing and mixing(dosing and mixing unit 1)
- Continuous Dry Granulation with the BRC Dry Granulator or
- Continuous Wet Granulation and drying via twin-screw pelletiser and true continuous drying
- Continuous dosing and mixing (dosing and mixing unit 2)
- Tableting
- Semi-continuous coating using KOCO®
Quality
- Higher quality through close-meshed inline control
- PAT integration and other process controls
- High level of process/product understanding
- Increased patient safety
- Less waste
- Lower costs for quality control
Cost savings
- Lower storage and transport costs
- Less space required for GMP rooms
- Fewer rejects, no need to discard entire batches
- Reduced API consumption in development
- Linking of several individual systems into one overall system
Flexibility
- Shorter development times, response to market demand
- Flexible batch sizes
- Changing requirements during the life cycle can be covered with the same machines
- Real-time release possible
Research & Development
- Shorter development times
- Lower product consumption
- No Scale-up problems
Operator safety
- Less interaction with raw materials
- Reduced dust exposure
- Increased safety
L.B. Bohle is revolutionising pharmaceutical production with continuous systems such as QbCon® 1 and KOCO 25, which enable end-to-end granulation, drying and Tablet Coating. These innovative solutions ensure the highest product quality, efficiency and flexibility with reduced use of resources and offer an ideal platform for research & development and high-volume production.
What is the main advantage of continuous production with QbCon® compared to traditional batch production?
The decisive advantage lies in the continuous Process Monitoring using PAT (Process Analytical Technology). This allows product quality to be monitored in real time and deviations to be recognised and corrected immediately. In contrast to batch production, complete batches do not have to be rejected or disposed of - this saves resources and increases safety.
Which pharmaceutical manufacturing processes are possible with the QbCon® system?
The QbCon® system from L.B. Bohle realises three continuous production processes: Direct compression, Wet Granulation with subsequent drying and Dry Granulation. The modular design allows customers to flexibly customise and combine their line.
What are the advantages of continuous manufacturing for the pharmaceutical industry?
Continuous manufacturing offers numerous advantages, including increased patient safety, lower production costs, improved process understanding and optimised process control. It also allows non-destructive 100% quality control in real time and can therefore significantly reduce approval times.
For which throughput ranges is the QbCon® system suitable?
The QbCon® system is designed for a throughput range of 5 to 25 kg/h. This makes it suitable for both clinical production and the commercial manufacture of solid dosage forms.
See for yourself and test our machines directly on site in our Service Centre and Technology Centre. Our competent and experienced team is at your disposal for test series or process optimisation in order totake your processes to a higher level. We offer you the opportunity to carry out practical tests to evaluate the efficiency, quality and Scalability of your processes. You benefit from state-of-the-art technology, comprehensive advice and customised support. Visit us and discover how our machines and processes can optimise your production processes and product quality.
Innovative technologies
As a technology leader for tablet production machines, we offer innovative solutions for every process step from development to large batches.
Customised solutions
L.B. Bohle develops and realises customised, highly complex machine solutions that are perfectly tailored to your requirements and production goals.
Support and customer service
L.B. Bohle is always at your side. With short response times and a clear focus on solutions, we are always reliably at your disposal - personally, competently and practically.
Sustainability
Sustainability is firmly anchored in all areas of the company. We make targeted investments in infrastructure and research to make our machines even more efficient and environmentally friendly.
High-tech pharmaceutical machinery "Made in Germany". With our extensive product portfolio, we optimise your pharmaceutical solids production. Find out more about the company now.
