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Continuous technologies pharma

The practice-proven MODCOS (Modular Continuous System) offers the optimal solution for modular and flexible continuous production processes.

Discover more about our MODCOS – Modular Continuous System.

MODCOS – Modular Continuous System

Modular continuous process technology for maximum efficiency, flexibility and product quality

With the Modular Continuous System (MODCOS), Glatt offers a flexible production system for the continuous manufacture of coated tablets – from product development to commercial production. The modular, multi-purpose system can be adapted precisely to the respective requirements, enabling short development times, rapid scaling, and maximum process reliability.

The system covers the entire process chain:

from precise excipient and API dosing to wet granulation and drying to tableting and tablet coating. All unit operations are seamlessly integrated into the central GlattView CONTI system control. Consistent product quality is controlled by Process Analytical Technology (PAT) or continuously monitored and controlled by closed control loops.

Thanks to fully automated, recipe-controlled processes, the process remains traceable at all times through track & trace functionality. At the same time, the modular system architecture enables fast product and batch changes – ideal for dynamic production environments.

  • Maximum flexibility through variability

    Individually configurable modular plant concept for different formulations, batch sizes, and production requirements

  • Consistent and reproducible product quality

    Fully automated, continuous process with process analytical technology (PAT) control

  • High efficiency and cost-effectiveness

    through reduced process steps

  • Seamless system integration and customized engineering solutions

    for perfect material flow

  • Transparent process management

    Complete traceability across the entire process chain

  • Wide range of formulations

    also for solvent-based recipes

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MODCOS Wet Granulation

Scalable technology for development, piloting, and production

The MODCOS xs-, s-, and m-line systems are specially designed for continuous wet granulation with subsequent drying. They are ideal for formulation development and initial feasibility studies – from powder to reproducible granules. The systems can be controlled manually, allowing process parameters to be tested flexibly and defined precisely.

Thanks to consistent scale-up strategies, the process parameters evaluated during the development phase can be seamlessly transferred to MODCOS production lines. Individually configurable process modules enable targeted adaptation to formulation requirements and production goals – from research and development to commercial manufacturing.

Minimal conversion effort, maximum economic benefit

Within the framework of the MODCOS concept, existing batch granulators from the GPCG series can be efficiently integrated into a continuous process chain.
This modular integration concept significantly reduces investment costs and opens up the possibility of gradually transitioning to continuous technology—without replacing existing equipment.

  • Modular & scalable process platform

    for development and production operations

  • Flexible process integration

    Expansion and adaptation according to formulation or production requirements

  • Suitable for solvent-based formulations and demanding pharmaceutical products

MODCOS Direct Compression

Precise dosing, stable process control, reproducible quality through continuous direct pressing

MODCOS offers flexible and customized solutions for continuous direct compaction. The various powder components are fed continuously and with high precision via gravimetric multi-ingredient dosing. The system automatically adjusts its hold-up to the respective throughput, ensuring that residence times remain stable and the process is optimally controlled.

Thanks to loss-in-weight dosing technology, the solid material flows are reliably controlled. In combination with Process Analytical Technology (PAT), the amount of material fed remains constant – process stability and reproducibility of product quality are guaranteed at all times.

The integration of downstream process steps such as tableting or capsule filling is carried out directly by Glatt in accordance with customer specifications. This creates a fully connected, continuous production line – from raw material dosing to the finished product.

Performance range: from 5 kg/h to 1,000 kg/h, scalable to individual production requirements.

  • Maximum flexibility

    for the entire portfolio thanks to easily adaptable modular system components

  • Safe operation for operating personnel

    thanks to Glatt’s own containment design up to OEB5

  • Quick and easy cleaning

    of the entire system for minimal product changeover times thanks to a well-thought-out design for efficient setup tasks