(47a) Lonza MicroReaction System – From Lab to Production

Microreactors open new pathways for the development of economical, innovative and efficient processes. Microreaction technology provides process intensification advantages through short mixing time, high heat transfer rates and precise control of reaction time. This has translated to higher yield, higher selectivity, safer operation, and new pathways for many reactions.

Bayer Technology Services (BTS) and Lonza Group Ltd. have teamed up to offer Lonza MicroReactor systems through Ehrfeld Mikrotechnik BTS GmbH. These reactors are especially designed for use under conditions that comply with Good Manufacturing Practices (GMP). Indeed several tons of products have been produced under GMP conditions using this microreactor system.

 The Lonza MicroReactor system is especially built for, but not limited to use in, the pharmaceutical industry. The system follows the toolbox approach, which has translated to flexibility for its users. The system provides integrated mixing, heat exchange and reaction in plates. Reactor plates can be easily replaced to change mixing structures, reactor volume and even change from single step to multiple step reactions. The system also allows expeditious scale-up of processes and faster time-to-market of products. One can study a reaction in a lab using the Labplate system, and subsequently transition to pilot and production using successively larger systems (Plate A6, Plate A5 and Plate A4).

 The collaboration between Lonza and BTS is providing an opportunity to redesign the reactors that marries the best traditions of both institutions.

 The presentation will introduce the microreactors conceptually, discuss their advantages and limitations, present the Lonza MicroReactor system and share examples of their application. The presentation will also discuss the Ehrfeld microreactor system and their applications.