For many pharmaceutical companies, continuous manufacturing offers clear advantages, including improved product quality, greater process understanding, reduced material consumption, and faster progression from development to commercial production. However, moving from theory to implementation can be challenging without access to the right expertise and equipment.
To help bridge this gap, Gericke and DFE Pharma have created an environment in Hyderabad that brings together formulation development expertise, excipient knowledge, and hands-on access to continuous manufacturing technologies. The goal is simple: help customers evaluate, develop, and optimize formulations using real equipment under real processing conditions.
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Why are hands-on trials important when evaluating continuous manufacturing?
Many pharmaceutical teams understand the potential benefits of continuous manufacturing but have limited opportunities to test formulations on industrial equipment before making larger investment decisions.
Hands-on trials allow manufacturers to move beyond theoretical assessments and generate practical process knowledge. Using their own formulations and materials, customers can evaluate feeding performance, blending behavior, process stability, and overall manufacturability under realistic operating conditions.
This practical approach helps reduce uncertainty, supports data-driven decision-making, and provides valuable insights for formulation development and process optimization. The experience gained during trials can also support future technology transfer activities and commercial manufacturing strategies.
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What makes the Hyderabad facility unique?
The Hyderabad facility combines two critical elements required for successful pharmaceutical development: formulation expertise and access to continuous manufacturing equipment.
While many organizations can provide equipment demonstrations or laboratory services, the Hyderabad setup enables customers to work directly with specialists while conducting trials on dedicated continuous manufacturing systems. This combination allows formulation challenges, process parameters, and excipient selection to be evaluated within a single collaborative environment.
Customers benefit from direct interaction with experts, rapid learning cycles, and the ability to explore different formulation approaches without having to establish their own continuous manufacturing infrastructure first.
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Which continuous manufacturing technologies can be evaluated?
The Hyderabad facility provides access to the key technologies required for continuous oral solid dosage manufacturing. Customers can evaluate continuous feeding, blending, refill solutions, process monitoring, and integration with downstream processing concepts.
The equipment is based on Gericke's continuous manufacturing technology, including the Gericke Formulation Skid (GFS), enabling realistic assessment of continuous manufacturing workflows from formulation development through potential commercial implementation. Test programs can be tailored to specific project goals, whether focused on early development, process optimization, or technology evaluation.
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How does combining formulation expertise with real equipment accelerate development?
Access to both formulation expertise and hands-on equipment trials can significantly accelerate product development. At the Hyderabad facility, customers can work with DFE Pharma’s formulation and excipient specialists while evaluating their formulations on Gericke’s continuous manufacturing equipment. This combination enables faster learning, practical process insight and informed decision-making, helping pharmaceutical companies progress efficiently from early development activities toward commercial manufacturing.
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Reducing Barriers to Continuous Manufacturing Adoption
One of the biggest challenges facing the pharmaceutical industry is not understanding the benefits of continuous manufacturing, but gaining the confidence and experience required to implement it successfully.
By combining formulation expertise, excipient knowledge, and hands-on access to continuous manufacturing equipment, the Hyderabad facility provides a practical pathway for companies looking to explore continuous manufacturing for oral solid dosage products.
Whether the objective is formulation development, process optimization, feasibility assessment, or technology familiarization, customers gain access to the resources, expertise, and equipment needed to make informed decisions and accelerate their continuous manufacturing journey
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