2025 AIChE Annual Meeting

(191d) Continuous Pharmaceutical Processing with Thin-Film Evaporation: Enhancing Scale-up Efficiency

The shift from batch to continuous processing is transforming pharmaceutical manufacturing by improving efficiency, product quality, and supply chain reliability. A critical challenge in this transition is integrating effective separation technologies that ensure process continuity and scalability. Thin-film evaporation offers a versatile solution for solvent recovery, concentration, and drying within continuous pharmaceutical workflows.

This presentation examines the role of thin-film evaporation in continuous drug substance and drug product manufacturing, focusing on key process parameters such as residence time, mass transfer efficiency, and thermal control. Case studies featuring the Rototherm system demonstrate its application in API processing, showcasing enhanced throughput, improved product uniformity, and robust process control. By optimizing thin-film evaporation for continuous operations, manufacturers can achieve greater process efficiency while maintaining stringent quality standards.