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CONSIGMA® FC FLEX

PRODUCTION-SCALE COATER

Accurate, efficient and modular film coating that scales directly from R&D to production.

Shorter time to market No redevelopment required GEA’s scale-out philosophy means no rework is necessary as process geometry is replicated from lab scale to full production.

Flexible production capacity Three exchangeable drums Process batches from 3 kg up to 90 kg per hour. Add coating modules to multiply production capacity as demand grows.

Three-dimensional coating Complete coverage of each tablet Tablets move through a three-dimensional cascade for uniform spray coverage. High air flows ensure near-instantaneous drying and efficient processing.

Small footprint Space-saving flush TTW configuration The CFC Flex is designed to minimize process-room space requirements, even when the loading and discharge systems are mounted within the wall plate. Rapid processing of small batches also enables shallower drums, reducing technical-room requirements.

CONSIGMA® FC FLEX COATER 90x

Micro-coats per minute every single pass

100% Tablet coverage coated in flight

6 min Complete batch cycle

2160 kg Throughput per day 24 hours per day

100% Coverage for full CIP

OEB6 ready Built for containment

Designed for production-scale batch and continuous tablet coating, the ConsiGma® FC Flex enables direct transfer from R&D to production, delivering the precision, flexibility and speed pharmaceutical manufacturers need.

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FC-FLEX LEAFLET FC-FLEX LEAFLET

Same drum diameter from lab to production, only wheel depth and nozzle count change. Geometrically identical process dynamics eliminate re-validation and scale-up risk at commercialization.

Multiple sublots reduce the quantity of “in-process” material to 9 kg or less, alleviating the risk of costly failures.

360˚ coverage on every pass, gentle even for soft and friable tablets. Tablets cascade and spin freely. Free-fall mechanics protect fragile products that conventional drum coaters would damge.

Tablets are lifted and sprayed individually rather than rolling over each other, eliminating the erosion that requires conventional coaters to over-apply.

Tablets are loaded directly into the coating drum. Fast, clean and simple.

01 LOADING 02 ROTATING 03 COATING 04 UNLOADING

High-speed drum and air-knife separate and spin tablets through the spray zone.

Microcoat applied 1.5x/sec in free-fall for uniform 360˚ coverage, dries instantly.

Batch fully discharged and ready for immediate packaging.

PRECISION TECHNOLOGY FOR TABLET COATING

Spray application

Scale out not scale-up

Rapid mini-sublots

The cascade

Accuracy by design

1.5x per second Up to 9 kg mini-batch, 2160 kg/day _<2% weight gain, 33% less coating material

Tablets pass the spray zone 1.5 times per second, applying multiple micro-coats that dry instantly, eliminating overwetting and ensuring perfect uniformity.

Scale-up from lab to full production in less than a single day

A 6-minute batch cycle means your team runs more iterations before lunch than most processes allow in a week. Step from R&D to validated production in the afternoon.

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EVERY COATING CHALLENGE TACKLED

Aesthetic coatings Color & brand identity Vibrant, uniform color coatings on complex shaped tablets with precise consistency across every batch; ideal for product differentiation and personalized medicine, such as minitabs.

Protective coatings API stability & shelf-life Barrier and moisture-protection coatings that shield the API from oxygen, humidity, and light; extending product stability and shelf-life.

Functional coatings Controlled & modified release Enteric, sustained-release and delayed-release coatings for precise pharmacokinetic profiles; developed on the same platform used at commercial scale.

Brand identity and patient compliance

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WIP as standard OEB6 with CIP options

CFC FLEX ADVANTAGES

High-speed drum and air-knife deliver even microcoating A microcoat is applied 1.5x per second. Erosion-free dynamics reduce coating usage from 3% to 2%.

Exchangeable wheels and modular spray lance Modular wheel technology provides 3:1 geometric scaleability from a single machine and a 9:1 operating window.

Integrated wash nozzles as standard Washing-in-place nozzles are integrated with all CFC units with simple upgrades to enable fully automated WIP or CIP cycles.

Critical process dimensions repeated for all capacities Only the Wheel depth changes across the range. Spray dynamics and process parameters stay identical from lab to production, eliminating costly re-validation.

Ideal for soft or friable tablets During the coating cycle tablets enter free-fall and gradually reconnect with the drum in a controlled manner. This gentle mechanism protects products that conventional drums could damage.

No PPE required, dust exposure eliminated BUCK® AC and MC valve technology allows loading and discharging of high-potency compounds with no operator risk and no expensive PPE. Dust emission is eliminated.

ConsiGma® coating technology

Flexible production capacity

Washing and cleaning in place

Linear scale-up to 9 kg sub-batches

Free-fall coating

Containment with BUCK® Split Valves

3:1 geometric scaleability 9:1 operating window ✓ soft tablets ✓ friable tablets

-33% coating solution needed 1.5x microcoats per second 9 kg production sub-batch 1:1 linear scale-up

0 PPE required ✓ no dust & cross-contamination

Six features that translate directly to faster, cleaner, budget-friendly development

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LINEAR SCALE-UP while keeping the same geometry

ConsiGma® FC Flex increases capacity by extending drum depth. Drum diameter and spray distance remain consistent from lab to production.​

ConsiGma® FC Flex

Same geometry at every scale Process parameters

carry over directly no re-validation

Different geometry at every scale Bed depth, spray flux and rotation all shift

re-validation required

Only drum depth changes diameter and spray distance stay identical across the full range

Conventional coater Diameter, spray distance and rotational speed all shift at every scale (illustrative, not to scale)

Lab scale

depth 80 mm

Pilot scale

depth 160 mm

Small production

depth 320 mm

Mid production

depth 480 mm

Lab scale

Pilot scale

Small production

Large production

constant

changing

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SCALE-OUT, DON’T SCALE-UP

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FOR GENERAL INQUIRIES GEA Pharma & Healthcare pharma@gea.com gea.com/contact

READY TO SEE WHAT IT CAN DO FOR YOU? GEA provides seamless, end-to-end production solutions tailored to your program.

Test your own formulation on the CFC Lab and CFC Flex. Experience direct transfer from lab to production, without scale-up

From powder to coated tablet

Book a live demo or run a trial

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© GEA Process Engineering nv 2025. All rights reserved. Subject to modifications. 10/26 V1.0 ConsiGma® & BUCK® are registered as trademarks in several countries worldwide.

GEA Pharma & Healthcare GEA Process Engineering nv Keerbaan 70, B-2160, Wommelgem, Belgium

Tel +32 2 350 1211 pharma@gea.com gea.com/contact

ConsiGma® coater scale-up

Conventional coater scale-up

Zero geometric parity from lab to production. Dimensions X & Z are consistent across the range. Dimension Y increases incrementally.

Zero geometric parity from lab to production

Typical dimensions

Lab scale Pilot scale Small production

Mid production

Multi-module large production systems

Product CFC Lab CFC Flex CFC Flex CFC Flex CFC Flex2 CFC Flex4 Drum diameter X mm X mm X mm X mm X mm X mm Drum depth (Y) 80 mm 160 mm 320 mm 480 mm 2 x 480 mm 4 x 480 mm Batch volume 2 litres 4 litres 8 litres 12 litres 2 x 12 litres 4 x 12 litres Spray distance Z mm Z mm Z mm Z mm Z mm Z mm Typical rpm 85rpm 85rpm 85rpm 85rpm 85rpm 85rpm Nozzles 1 nozzle 1 nozzle 2 nozzles 3 nozzles 2 x 3 nozzles 4 x 3 nozzles Cycle time from 6 mins from 6 mins from 6 mins from 6 mins from 6 mins from 6 mins Cycles/20h day 200 200 200 200 2 x 200 4 x 200 Sublot weight 1.5 kg 3 kg 6 kg 9 kg 9 kg 9 kg 24h throughput 300 kg 600 kg 1200 kg 1800 kg 3600 kg 7200 kg

Typical dimensions

Lab scale Pilot scale Small production

Large production

Drum diameter 200 -330 mm 610-760 mm 765-1,110 mm 1,400-1,980 mm Drum depth (Y) 70-180 mm 350-460 mm 630-1,160 mm 1,030-1,900 mm Mouth opening 120-230 mm 130-380 mm 375-590 mm 600-850 mm Batch volume 0.5-5 litres 15-75 litres 30-160 litres 250-1000 litres Nozzle to bed 100-200 mm 150-250 mm 200-280 mm 250-350 mm Typical rpm 12-30 rpm 6-20 rpm 4-15 rpm 2-10 rpm # Nozzles 1 nozzle 1-3 nozzles 2-5 nozzles 4-8 nozzles Typical cycle time 1-1.5 hours 2 hours 2 hours 2.5 hours Realistic cycles/24h – – 10 8 Typical batch weight – – 100 kg 500-600 kg Daily throughput – – 1,000 kg 4,800 kg

SCALE-OUT, DON’T SCALE-UP

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