Overview

In today’s fast-evolving pharmaceutical industry, the shift from traditional batch processes to continuous flow synthesis has become a game-changer. Continuous flow technology offers numerous advantages, including increased efficiency, enhanced safety, reduced production costs, and improved product quality. As the demand for faster, more reliable, and scalable production processes grows, scientists and process engineers in the pharmaceutical industry are seeking ways to leverage the full potential of flow chemistry. To address this need, we at Glostem, are proud to present the masterclass “Scaling-up Flow Synthesis – Developing Powerful Continuous Processes for Pharmaceuticals.”

This masterclass is specifically designed for scientists, process developers, and R&D professionals working in the pharmaceutical, agrochemicals, fine-chemicals and petroleum industries who are eager to deepen their knowledge of flow chemistry and learn how to successfully scale up lab-scale reactions into industrial-scale continuous processes. The masterclass will provide participants with essential theoretical knowledge, practical tools, and insights into overcoming common challenges faced when scaling-up flow synthesis.

A major focus of the masterclass will be on the critical aspect of scaling up flow synthesis from the lab to industrial production. Scaling up is not simply a matter of increasing the size of the reactor; it requires careful consideration of factors such as heat and mass transfer, mixing efficiency, and reactor design. Participants will learn about the challenges encountered during the scale-up process and how to optimize reaction conditions to ensure a smooth transition from small-scale to production-scale processes. Techniques for designing reactors that maintain consistent performance at larger scales will also be discussed.

Additionally, the masterclass will delve into developing robust continuous processes that are reliable, efficient, and scalable. Participants will explore strategies for optimizing reaction conditions, managing solvents and reagents, controlling impurities, and recycling catalysts, all while ensuring that the processes meet stringent pharmaceutical manufacturing standards. Attention will be given to the integration of process analytical technologies (PAT) and quality control measures to ensure that continuous flow processes meet the regulatory requirements of global agencies such as the FDA and EMA.

This two-day workshop on flow chemistry will provide three content sessions per day (90 min each) as well as a concluding Q&A session. On day 1, the fundamentals behind flow chemistry will be briefly highlighted to ensure participants have the same knowledge base on important concepts such as heat & mass transfer, mixing and residence time. Next, a selection of high and low-temperature applications will be discussed which shows how these concepts can be exploited in miniaturized flow reactor set-ups. This will entail information on the type of flow reactor, the materials used, and the configuration to best meet a given need. Important aspects such as reaction scale-up, process intensification, safety, and reaction streamlining will be highlighted and discussed on the chosen case studies. The last session on day 1 will discuss several hazardous chemistry applications whereby flow reactors provide for increased safety due to miniaturization, in situ generation and quench of reactive intermediates, and the use of inline PAT to inform the flow process optimization.

On day 2 the focus will shift towards using heterogeneous conditions in flow applications such as the use (or generation) of solids and gases as well as various related biphasic scenarios. This will then lead to discussions on multi-step reactions performed in flow mode via telescoping and integrated inline purification strategies. The scalability to generate kilogram quantities of products will be an integral component of this session. Lastly, a number of recent flow applications for the scaled generation of APIs will be highlighted. This will focus on the underlying chemistry and the development of a powerful continuous process as well as on regulatory aspects and development time implications. 

Overall, this masterclass offers a comprehensive training opportunity for pharmaceutical scientists and engineers who are looking to harness the power of flow chemistry to scale-up processes effectively. By the end of the session, participants will have the knowledge and tools needed to develop continuous processes that are efficient, scalable, and compliant with regulatory standards. This masterclass will be an invaluable resource for those looking to drive innovation and streamline production in pharmaceutical manufacturing.

Contacts

Technical Query: Ms. Tavleen Thakur, M: 7696125050, Email: t.thakur@glostem.com
Participation Query: Ms. Swati Kanwar, M: 8289015050, Email: s.kanwar@glostem.com
                                       Ms. Farheen, M: 7696225050, Email: f.zainab@glostem.com