This enhanced collaboration has led to the ConsiGma® CDC Flex system, a next-generation platform developed to make continuous direct compression (CDC) more flexible, efficient, and cost-effective.

First shown in early October at the GEA/Hovione Advancing Continuous Tableting Seminar, the new system was then presented to a broader audience at the CPHI Frankfurt trade show. This step marks an important milestone in the partnership between the two companies.

The ConsiGma® CDC Flex represents a major leap forward in the development and production of oral solid dosage forms. Together, GEA and Hovione have developed a versatile system and a suite of automated tools — known as SimpleCT — that simplify operation, enhance efficiency and containment, and improve operator safety. These innovative developments were designed with versatility and user-friendliness in mind, and to provide a simpler workflow with automated controls and smart interfaces.

Three different process configurations

The CDC Flex is designed to operate in three different process configurations — continuously at low or high throughput, or in batch mode with immediate direct compression of pre-blended product — at output rates of 1–200 kg/h. It can also handle R&D batches as small as 1.5 kg. This is enabled by the ability to swiftly switch between different-sized continuous blenders within a single unit.

systems for food beverage — **The new ConsiGma® CDC Flex delivers unprecedented flexibility, simplicity, and cost-efficiency in continuous direct compression. (Photo: GEA)**

“This brand-new addition to the ConsiGma® portfolio has been designed as a truly versatile system that offers both high and low throughput functionality,” said Dr Jim Holman, Senior Director Technology Management, GEA Pharma Solids. “This agility makes the CDC Flex ideal for both R&D projects and commercial-scale production runs. In addition, for companies with a wide product portfolio that wish to benefit from the advantages that CDC offers, we now have a solution: ultimate flexibility in continuous direct compression.”

“We believe that continuous tableting delivers significant value to our customers, primarily by accelerating time-to-market through a compressed development phase and by enhancing supply chain flexibility. It also helps to reduce development costs while improving product quality and sustainability,” said Filipe Gaspar, Vice President of Technology Intensification at Hovione. “Through our collaboration with GEA, we aim to advance the continuous production of oral solid dosage forms, making the technology more standardized, accessible and cost-efficient for pharmaceutical customers.”