The pharmaceutical industry today is experiencing a paradigm shift from batch to continuous manufacturing, which promises greater flexibility to target diverse populations, as well as more-consistent product quality to ensure best efficacy. However, shifting to continuous processing means that even basic process steps, such as feeding, can become unexpected but are crucially important. In this review, we will present the fundamental differences between dispensing (batch) and feeding (continuous) and how they impact the formulation design space. We will further outline our rational development approach, applicable to continuous unit operations in general, which includes standardized material and process characterization, as well as predictive modeling based on advanced, multidomain simulation tools.

• Research Center Pharmaceutical Engineering GmbH
• Graz University of Technology
• European Consortium for Continuous Pharmaceutical Manufacturing, consisting of UCB Pharma SA, Merck KGaA, Orion Pharma, Boehringer Ingelheim Pharma, and F. Hoffmann-La Roche Ltd, GEA Group

• Oral solid dose
• Material characterization

1. Continuous powder feeding
2. Material characterization
3. material science
4. oral solid dose
5. Research Article
6. Solid dosage form