FlowKiloLab®
GMP-Compliant Precision in Flow Chemistry
In a recent application, FlowKiloLab® was implemented to optimize the production of a pharmaceutical intermediate requiring high precision and strict GMP compliance. The process demanded accurate dosing of both liquid and gas reactants, precise temperature control, and robust pressure management to ensure consistent product quality.
FlowKiloLab®
Optimizing Small-Scale Continuous Manufacturing
FlowKiloLab® was equipped with advanced liquid and gas dosing modules that enabled mass flow control with unparalleled accuracy. The system’s reactor modules, including both coil reactors and fixed-bed reactors, facilitated versatile processing. Operating at temperatures ranging from -20°C to 200°C and pressures up to 100 bar, the system handled a wide variety of reactions seamlessly.
One of the key challenges was maintaining consistent reaction conditions to avoid deviations in product quality. FlowKiloLab® overcame this through its maintenance-free pump design, which minimized dead volume and ensured smooth operation. Additionally, the system’s Kenics and Fluitec static mixers provided excellent mixing efficiency, enhancing reaction performance and yield.
The control system met GAMP 4 standards for data integrity, offering real-time monitoring through a local historian for trending and event recording. This ensured that all process data was accurately logged and readily available for audits. Cleaning and maintenance were simplified with easy dismounting options for T-probes and P-probes, reducing downtime and ensuring compliance with GMP protocols.
The modular nature of FlowKiloLab® allowed for quick integration of additional units, such as solid-liquid-gas reactors for hydrogenation reactions or Corning AFR plate reactors for specialized processes. This flexibility enabled the system to adapt to evolving production needs without significant reconfiguration.
Module Type Package (MTP) Integration
Microinnova’s FlowKiloLab embraces the principles of modular automation through the implementation of Module Type Package (MTP) standards. MTP provides a vendor-neutral framework that enables seamless integration of modular process equipment into higher-level control systems, such as Distributed Control Systems (DCS) or Supervisory Control and Data Acquisition (SCADA) systems. By encapsulating the functional description, interfaces, and services of each module, MTP facilitates plug-and-produce capabilities, allowing for rapid configuration and reconfiguration of process modules. This approach significantly reduces engineering efforts, accelerates time-to-market, and enhances the flexibility and scalability of production processes. By leveraging MTP, FlowKiloLab ensures efficient and adaptable process development, aligning with the evolving needs of modern manufacturing environments.
By implementing FlowKiloLab®, the client achieved:
- Improved process efficiency through continuous manufacturing.
- Enhanced product quality with precise control over reaction conditions.
- Full GMP compliance, ensuring regulatory standards were met.
- Reduced downtime due to streamlined cleaning and maintenance processes.
FlowKiloLab® provides a reliable, compliant, and highly adaptable solution for small-scale flow manufacturing, setting a new standard for precision and efficiency in chemical production.
FlowTonPlant
Plug-and-Produce Made Simple
FlowTonPlant delivers a quick and flexible scale-up by using a modular approach for unit operations, where a plant can be composed of prequalified plant modules. Manufacturing tasks and rapid-response production can be executed in a short time. A flexible modular automation approach based on the supplier-independent MTP technology ensures easy reconfiguration and smooth integration across suppliers, enabling “plug-and-produce”, allowing clients to respond instantly to market demands.
With our FlowTonPlant, each module offers services to the central unit, the Process Orchestration Layer (POL). This ensures fast setup, easy reconfiguration, and high interoperability. This empowers process engineers to configure and run systems without relying on dedicated automation specialists. Microinnova offers a future-proof solution for chemical and pharmaceutical manufacturing.
Plug. Produce. Customize. Repeat.
Photo credit: COPA-DATA
microinnova Engineering
Your competent partner
for flow plants and continuous manufacturing solutions
Manufacturing Strategies
In continuous manufacturing and process intensification
Skid-Based Plant Systems
Decreased Reactor Volumes via Process Intensification
By reducing reactor volumes through process intensification, we enhance safety and enable more compact plant designs. Smaller reactors mean reduced risk and more efficient use of space.
Utilization of Walk-In Fume Hoods as Manufacturing Infrastructure
We leverage walk-in fume hoods for manufacturing, significantly cutting infrastructure costs. This approach allows for safe and contained processing without the need for extensive facility modifications.
Adoption of Modular Plant Systems
Our modular plant systems speed up time-to-market and offer exceptional flexibility. Modules can be rearranged or expanded to meet changing production needs, ensuring agile manufacturing.
Implementation of the MTP Protocol
Small-Scale Manufacturing within Walk-In Fume Hoods
We facilitate small-scale manufacturing within walk-in fume hoods, reducing time-to-market and increasing operational agility. This allows for quick adjustments and efficient process testing.