GEA and Hovione have expanded their long-standing partnership with the launch of the ConsiGma CDC Flex system — a next-generation continuous direct compression (CDC) platform designed to deliver greater flexibility, simplicity and cost-efficiency in the development and production of oral solid dosage forms.

The new system, presented at the GEA/Hovione Advancing Continuous Tableting Seminar in early October and later showcased at CPHI Frankfurt, sets new standards for continuous tableting.

Developed together by GEA and Hovione the ConsiGma CDC Flex system incorporates 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,” the companies said.

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, with the ability to swiftly switch between different-sized continuous blenders within a single unit.

Dr Jim Holman, Senior Director Technology Management, GEA Pharma Solids, described the platform as a breakthrough for customers seeking flexibility. “This brand-new addition to the ConsiGma portfolio has been designed as a truly versatile system that offers both high and low throughput functionality. 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,” he stated.

Filipe Gaspar, Vice President of Technology Intensification at Hovione, noted that continuous tableting offers substantial benefits, including accelerated time-to-market, reduced development costs and improved product quality and sustainability.

“Through our collaboration with GEA, we aim to advance the continuous production of oral solid dosage forms, making the technology more standardised, accessible and cost-efficient for pharmaceutical customers,” he added.