Our Continuous Manufacturing Modules combine high precision loss in weight feeders with scientifically designed compact mixers and integrated PAT solutions.
The module can supply mixtures of up to 6 components to:
Gericke continuous mixing process technologies are ideally suited to the new era of efficient solid dose pharmaceutical manufacturing. Our systems are fully developed, and in use at various sites and have been approved by customers and the FDA.
|General: Strengths of continuous processing in the context of mixing solids||Relevance for pharmaceutical solids production|
|Same equipment during clinical trials and commercial production||Shorter development time, as the same feeding/mixing module is used. No scale up needed. To increase the "batch size", you extend the production time.|
|Easy to integrate into an existing continuous process.||Compression, extrusion and roller compacting become continuous processes.|
|Continuous mixing system takes up less space, thanks to the compact dimensions of the equipment.||Amount of space required by a feeding/mixing module for 4-6 components is 2*2*2 meters|
|Less risk of demixing, as the process volume is smaller and there is no need to empty large-volume batch mixers or intermediate tanks. Much less material is stored temporarly.||Continuous mixer with a volume of 1-10 litres. Production time required to turn the raw material into a tablet = 5 minutes - "process intensification".|
|The fully automated process cuts operating costs. The manufacturing process and the product quality are assured by means of sophisticated measurement and control technology.||The continuous feeding and weighing technology represents an integrated P(process) A(nalytical) T(echnology) solution that can ensure a formulation accuracy of 0.1 - 0.5% thanks to its high-resolution timing and weighing.|
|Improved product quality - the highly homogeneous shear rate and limited residence time distribution mean that the product is subject to very even levels of stress.||Very gentle processing of sensitive products thanks to low speeds and minimal drop heights as well as short mixing times of less than 30 seconds.|
Advantages of our module
GZD100.12 0.05 kg/h - 2.5 kg/h
GZD200.12 0.5 kg/h - 25 kg/h
GZD200.22 5 kg/h - 100 kg/h
GZD300.32 20 kg/h - 200 kg/h
Even cohesive products are dosed accurately and reliably. The feeder can be delivered as single machine or as part of a fully integrated continuous feeding and mixing station for multiple components formulas.
EasyDos Pro Controller
EasyDos Pro controller monitors the feed rate at a high sampling rate and adapts speed of feeding screws to achieve highest accuracy with low relative standard deviation RSD. It uses unique filter algorithms to assure robust and precise feeding, even with varying bulk material properties and external disturbances. We also include the right tools for an independent validation of feeder performance.
Gericke Continuous Mixers GCM offer the optimum combination of radial and axial mixing (dispersion), ensuring highest homogeneity with low RSD. The shape, layout and adjustment of the Gericke mixing tools have been developed based on upon 50 years of experience in continuous mixing and in collaboration with universities.
The Gericke Continuous Mixer is designed as a continuous mixer with modular components. The residence time and the energy input can be adjusted easily.
GCM 800 ECD:
1 - 25 kg/h
5 - 500 kg/h
100 - 1000 kg/h