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CONSIGMA® FC LAB

Accelerate your formulation development with our ultra-efficient, highly accurate R&D Film Coater.

Shorter time to market Single day process development What takes usually weeks, GEA does in a day. Process development can be completed in a single session.

Lower development costs One platform from R&D to production No intermediate equipment. Minimize time and cut waste by more than 90%.

Simple transfer to production What works in the lab works at full scale The lab and commercial platforms are geometrically identical. Parameters from R&D apply directly to production.

Higher revenue and faster ROI Better returns Every week saved in development is a week of revenue gained; minimal product waste during scale-up makes the financial case clear.

CONSIGMA® FC LAB COATER 90x

Micro-coats per minute every single pass

100% Tablet coverage coated in flight

6 min Complete batch cycle

90% Less material waste vs conventional coating processes

Zero Scale-up rework

OEB4 ready Built for containment

Designed for R&D batch and continuous tablet coating, the ConsiGma® FC Lab gives pharmaceutical manufacturers the precision and speed to bring better products to market faster.

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CFC-LAB LEAFLET CFC-LAB 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.

Rapid batch times minimize tablet attrition and maximise throughput. A complete DoE can be completed in a single working day.

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 causes 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

Lower development costs

The cascade

Accuracy by design

1.5x per second <6 min batch cycle _<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.

A complete Design of Experiment in a single day

A 6-minute batch cycle means your team runs more iterations before lunch than most processes allow in a week. Go from first run to optimized parameters in one session.

3 GEA PHARMA & HEALTHCARE TABLET COATING

CFC-LAB LEAFLET

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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1 platform for all processes ✓ CapEx OpEx reduced

CFC LAB ADVANTAGES

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

80 mm wheel sized precisely for development, no API waste Batch sizes from 0.5 to 1.5 kg allow thorough characterization of coating behavior without consuming expensive API material.

Single platform for automation and air handling A unified platform covers both fluid bed processing and tablet coating, removing the need for duplicate systems. Operator compliance improves and R&D floor space delivers greater output per m2.

Same drum diameter as production coaters Only wheel depth changes for larger batches. 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 would 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 expensive PPE. Dust emission is eliminated.

ConsiGma® coating technology

Batch sizes 0.5–1.5 kg

Integration with AirConnect platform

Linear scale-up to 9 kg sub-batches

Free-fall coating

Containment with BUCK® Split Valves

0.5-1.5 kg batch range 80 mm wheel diameter ✓ 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

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CFC-LAB LEAFLET

SEAMLESS INTEGRATION

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CFC-LAB LEAFLET

The CFC Lab is an integral element of GEA’s AirConnect platform, a modular system supporting fluid bed drying, granulation, and coating processes, with batch capacities from 100 g up to 10 kg, from early development to pilot production.

This unified system delivers major cost and compliance benefits versus conventional unit operations: one system to qualify, calibrate and maintain.

The CFC Lab works as part of GEA’s AirConnect platform for fluid bed drying, granulation and coating from 100 g to 10 kg.

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CFC-LAB LEAFLET

GEA AIRCONNECT PLATFORM

Fluid bed drying High performance drying with GEA’s overlap gill plate technology.

From 100 g

Top spray granulation Conventional top spray granulation. A proven process improved with GEA technology.

From 100 g

FlexStream Side spray granulation & pellet coating. Superior quality, linear scale-up.

From 500 g

Precision-Coater Bottom spray for micro-pellet and particle coating. Minimal agglomeration.

From 500 g

CFC Lab Coater Innovative film coating with 6-minute cycle times, uniform coating and linear scale-out.

0.5–1.5 kg

GEA AIRCONNECT PLATFORM One R&D platform. From powder to coated tablet.

From 100 g to pilot. No equipment change. GEA’s modular design ensures accurate control throughout the capacity range. The same control unit governs every module.

Switch process, not platforms. Drying today, granulation tomorrow, tablet coating next week. Each module connects to the same AirConnect control unit.

Tablet coating completes the portfolio. The CFC Lab Coater brings rapid film coating to AirConnect, completing the full OSD R&D workflow in one platform.

Fluid Bed Drying Top Spray Granulation Flexstream

Precision-CoatingFluid Bed Drying Top Spray Granulation Flexstream

Precision-CoatingFluid Bed Drying Top Spray Granulation Flexstream

Precision-CoatingFluid Bed Drying Top Spray Granulation Flexstream

Precision-Coating

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CFC-LAB LEAFLET

FOR GENERAL ENQUIRIES 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.

See the CFC Lab Coater run a full DoE in real time at our pharma test center. Test your formulation with GEA.

From powder to coated tablet

Book a live demo or run a trial

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© GEA Process Engineering Ltd 2026. All rights reserved. Subject to modifications. 04/26 V1.0 ConsiGma® & BUCK® are registered as trademarks in several countries worldwide.

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Tel +44 23 8026 7131 pharma@gea.com gea.com/contact

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