Continuous Flow Technology

Overview

Figure 1. Diagram of continuous
flow manufacturing ^[1].

As an innovative technology, continuous flow technology has recently gained momentum in the pharmaceutical industry. Continuous flow simply is the performance of chemical reactions in a pipe or tube rather than in a traditional batch stirred vessel, or as a cascade using continuous stirred tank reactors (CSTR) ^[1]. This streamlined approach offers numerous advantages over batch processing, making it an attractive option for the production of complex molecules such as APIs and intermediates in the biopharmaceutical industry.

Main Advantages

Improved Efficiency

Continuous flow technology allows for faster reaction times and higher yields compared to traditional batch processes. By continuously pumping reagents through a reactor, reactions can be completed in a shorter amount of time, leading to increased productivity and reduced production costs. This efficiency is crucial in the fast-paced biopharmaceutical industry where speed and accuracy are paramount.

Enhanced Safety

Flow chemistry can enhance safety in chemical manufacturing by reducing the risk of accidents associated with handling large quantities of reactive intermediates. Continuous flow systems typically operate under controlled conditions, minimizing the potential for runaway reactions or hazardous incidents.

Scalability

Continuous flow systems are often more easily scalable than batch processes. By simply adjusting the flow rates or reactor dimensions, manufacturers can scale production volumes without significant changes to the process. This scalability is particularly advantageous for transitioning from lab-scale synthesis to large-scale production.

Reduced Environmental Impact

Flow chemistry offers the possibility to realize greener and more sustainable production processes. By optimizing reaction conditions and minimizing waste generation, continuous flow systems can reduce the environmental impact of chemical synthesis.  In addition, flow chemistry further promotes sustainability by enabling the use of highly reactive or hazardous reagents in a safer and more controlled manner.

Supportable Reactions

Our company has successfully applied continuous flow technology to a variety of reaction types. These types include, but are not limited to:

The comprehensive continuous flow technology platform established by our company can provide a series of technical services for projects from preclinical to commercial stages, such as feasibility assessment of flow chemistry, process development and optimization, verification and up-scaling, and process transfer. If you have any need, please feel free to contact us.