ContinuousPlant® Software Suite
Our ContinuousPlant® Software Suite is uniquely engineered for modular continuous manufacturing processes and skids enabling the seamless integration of in-process Process Analytical Technology (PAT) orchestrations with advanced process control, and real-time materials traceability and tracking systems. Through years of research and development, Continua created this innovative Process Orchestration Layer (POL) software to enable the life sciences industry, and their process equipment OEMs to consistently produce drug products more efficiently, faster, and of better quality than traditional batch manufacturing methods.
A strategic advantage of ContinuousPlant Software Suite is its ability to allow users to easily integrate unit equipment such as feeders, blenders, and tablet presses from different suppliers into a single process automation system giving one the freedom to select the equipment best designed to handle the specific material characteristics of the drug products, APIs or biologics being manufactured.
The inherent modularity of ContinuousPlant Software Suite’s object-oriented programming architecture maximizes user flexibility by allowing for the interchangeability of unit operations while incorporating globally accepted S88 batch control standards and terminology to enhance its ease of use. The number, type, and order of the process units are simply determined by a single recipe without requiring additional programming or validation. This allows users to create a recipe quickly and easily in a drag-and-drop format similar to creating a Visio diagram, then configure the units within the recipe via simple drop-down menus.
ContinuousPlant Software Suite can run multiple products with different processes on a single continuous manufacturing line through its recipe control feature. In the case of OSD manufacturing, this feature allows users to make a product using dry granulation one day and a different product using wet granulation the next. This unique modular, multi-product flexibility is built into ContinuousPlant Software Suite and validated as a part of the system.
In addition to incorporating S88 software architecture to maximize its modularity, flexibility, and ease of use, ContinuousPlant Software Suite offers two essential data management functions uniquely designed for controlling continuous processes – materials traceability and tracking. To accurately trace raw material concentrations and lot numbers in real-time throughout the process, each unit operation is assigned a Residence Time Distribution (RTD) model. The concentrations and lot numbers are recorded and stored to allow finished products to be traced back to lot material lots with a high degree of accuracy.
Each ContinuousPlant Software Suite solution is configured by our expert systems engineers to meet your CM user requirements specification.
Turnkey Direct Compression Skids
Coperion K-Tron has partnered with process automation and software experts Emerson and Continua Process Systems to provide highly versatile, turnkey continuous direct compression skids for pharmaceutical and biotech manufacturers.
These ultramodern modular skids are state-of-the-art fully integrated platforms that include all the hardware and software necessary for a complete direct compression tableting continuous manufacturing line. Best of all, the platforms are designed for complete modularity of the hardware and software to allow end users the flexibility to select different processes including dry and wet granulation, different unit operations, plus the ability to manufacture multiple products on a single skid.
Continuous Manufacturing Partners
Emerson is the leading supplier of automation solutions to the Life Sciences industry, with automation expertise and technologies to solve your greatest cGMP manufacturing challenges. Emerson has effective technology solutions for improving your real-time product quality, reliability, and operating costs. From design to implementation, and start-up to on-going optimization, you can rely on Emerson to stay competitive in a global economy.
Emerson’s DeltaV distributed control system (DCS) is an easy-to-use automation system that simplifies operational complexity and lowers project risk. The state-of-the-art suite of products and services increases continuous manufacturing performance with intelligent control that is easy to operate and maintain. The DeltaV DCS adapts to meet your needs, scaling easily without adding complexity.
With over 4,500 feeders installed worldwide in the pharmaceutical industry, and the development and subsequent update of the first true pharmaceutical design Loss-In-Weight (LIW) feeder for continuous processing, Coperion K-Tron has become the global leader in providing sophisticated solutions with state-of-the-art equipment.
The collaboration with process automation and software experts Emerson and Continua Process Systems enable us to provide highly versatile, turnkey continuous direct compression skids for pharmaceutical and biotech manufacturers. These state-of-the-art platforms are designed for complete modularity of the hardware and software to allow end users the flexibility to select different processes including dry and wet granulation, different unit operations, plus the ability to manufacture multiple products on a single skid.
Founded in 2006, the Center for Structured Organic Particulate Systems (C-SOPS) brings together a cross-disciplinary team of researchers from major universities to work closely with industry leaders and regulatory authorities to improve the way pharmaceuticals, foods and agriculture products are manufactured. C-SOPS focuses on advancing the scientific foundation for the optimal design of SOPS with advanced functionality while developing the methodologies for their active control and manufacturing.
Headquartered at Rutgers University, C-SOPS partners include the New Jersey Institute of Technology, Purdue University, the University of Puerto Rico at Mayaguez, and more than 40 industrial consortium member companies including Continua Process Systems and Emerson.
Integra CMS is the leading provider of comprehensive scientific and technical support to manufacturers who seek to formulate, implement, or optimize continuously manufactured products. Their top network of global universities, industrial partners, and technology suppliers are here to deliver tailored, effective continuous manufacturing solutions. Integra applies a step-by-step approach to help pharmaceutical manufacturers create efficient systems through effective integration of multiple methods and tools to meet key objectives, including maximum process understanding and maximum product quality at minimal cost.
Informetric Systems Inc. develops software applications that enable manufacturers to improve quality and increase productivity. Informetric software provides data acquisition and reporting for critical product release activities in batch and continuous GMP manufacturing facilities.