GEA - ConsiGma—Granulation

ConsiGma™ 1 Lab Scale Continuous Wet Granulation & Drying


ConsiGma™ 1 - lab-scale continuous wet granulation and drying for fast and low cost R&D

In 2008, GEA Pharma Systems introduced ConsiGma™, an innovative continuous high-shear granulation and drying concept capable of producing pharmaceutical granules continuously, without start-up and shut-down waste. This continuous high-shear granulation and drying concept enabled the use of the same granulation and drying system for development and production work without the need for scale-up, as the determining factor for batch size is running time – not the size of the equipment. Batch sizes ranging from a couple of kilogrammes up to several tonnes could be produced.

Continuous high-shear granulation and drying for R&D

In early research and formulation development however, the availability of the active ingredient is often very limited and there is always a need for process equipment that is capable of producing only a couple of hundred grams to develop new drug formulas. 

Continuous high-shear granulation and drying at gram scale

In response to this need, GEA Pharma Systems developed ConsiGma™-1, the lab-scale version of the ConsiGma™ continuous high-shear granulation and drying concept. This system consists of a patented continuous high shear granulator equipped with all necessary auxiliaries to allow the development of the granulation process. A small dryer equal to one drying segment of the ConsiGma™ production dryer and capable of handling 0.5 to 1.5kg of granules, can be added to the lab machine, creating a unique combination with integrated controls for the development of continuous processes. 

Quick and Simple Granulation Scale-up

ConsiGma™-1 is capable of running batches of a couple of hundred grams up to 5 kg (or more if necessary), with less than 10 g of product held up in the process and less than 80 g of product losses. Because of the fast processing times, minimal retention times and flexibility of the system, it is ideal for developing the formula and process parameters using Design of Experiments. The process parameters developed with ConsiGma™-1 can be directly transferred to the full ConsiGma™ system. 

The system is designed for fast and easy deployment in R&D labs.