Continuous reactors, as a central component of continuous manufacturing, offer numerous advantages in terms of efficiency, quality control, and cost-effectiveness. These systems enable the continuous production of pharmaceutical drugs, biologics, and other biotech products, allowing for more consistent product quality, reduced production costs, and shorter time-to-market.
There are different types of continuous reactors used in pharmaceutical and biotech manufacturing, including:
- Continuous Microreactors – High efficiency continuous microreactors (HeCM) for small and large volumes are available, and can be customized as per requirements.
- Plug Flow Reactors (PFR): Commonly used for reactions in which the flow is continuous and unidirectional, often preferred in scenarios where fast, highly efficient reactions are required.
- Fixed Bed Reactors: Often used in catalysis or biochemical processes, these reactors involve a stationary bed of catalyst material through which reactants flow, and products are continuously removed.
- Membrane Reactors: These reactors incorporate a semi-permeable membrane, allowing for selective separation of products or reactants as the reaction proceeds.
In the context of pharmaceutical and biotech manufacturing, continuous reactors are employed for both chemical synthesis and bioprocessing (e.g., fermentation and cell culture processes).
Key Advantages of Continuous Manufacturing with Continuous Reactors
- Consistent Product Quality
- Reduced Time-to-Market
- Scalability
- Improved Efficiency
- Real-time Monitoring and Control
- Smaller Footprint
Applications
- Synthesis of Active Pharmaceutical Ingredients (APIs)
- Production of Biologics
- Catalytic Reactions
- Continuous Flow Synthesis of Drug Precursors
- Fermentation Processes
- Cell Culture Production
- Continuous Downstream Processing