Microinnova implemented a continuous API synthesis solution for a 2nd generation API synthesis process, reducing the number of unit operations by half. By applying flow chemistry and process intensification techniques, processing times were shortened by a factor of up to 10, significantly improving efficiency and safety.
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The optimized process addressed challenges such as fast exothermic reactions and hazardous chemistries by enhancing mass and heat transfer through specialized reactor designs.
In one project, the number of unit operations was reduced from 18 to 9, and solvent usage was cut from 14 kg to 7 kg per kg of product by eliminating chlorinated solvents. This reduction in by-product formation led to fewer work-up steps, enabling three to four synthesis steps to be executed sequentially without intermediate separation. The efficiency gains resulted in reduced working capital, less variability in batch quality, and improved safety due to smaller reactor volumes and enhanced process control.
The use of Process Analytical Technology (PAT) tools further ensured consistent product quality and real-time monitoring. Additionally, hazardous reagents were generated in situ, eliminating the need for storage and enhancing safety. Microinnova’s innovative approach to continuous manufacturing delivers streamlined, efficient, and safer API synthesis processes, demonstrating the transformative potential of process intensification.