Pioneering: Takeda’s Leap into Next-Gen Pharmaceutical Development

November 28, 2024

The drive for efficiency and innovation propels the scientists and engineers at companies like Takeda Pharmaceuticals to challenge conventional processes.

Led by the synthetic molecule R&D team based in Cambridge, MA, the project was born from a visionary ambition: to establish a library of lab-scale unit operations, freeing the team to concentrate on chemistry rather than the logistical intricacies of module construction and to be able to quickly pivot to new target molecules without requiring additional hardware. This vision materialized in compact modular subframes housing continuous stirred tank reactors (CSTRs) ranging from 250 mL to 1 L, complemented by a custom-made ultra low-rate solids feeder, and a high temperature adjustable volume plug flow reactor (PFR).

However, turning this vision into reality presented formidable challenges. Accommodating all components within limited space necessitated meticulous planning and extensive collaboration among the team, engineers, and shop personnel. Overcoming spatial constraints while ensuring ergonomic efficiency demanded innovative solutions. Aluminum framing, offering both flexibility and structural integrity, was employed, while 3D scanning technology ensured precise fitting within the designated space.

Electrical panel design posed another challenge, requiring extensive upfront work to minimize size and ensure compatibility with each sub-module.

Nevertheless, the project yielded remarkable success. A standout feature of the plant is its modular control system, allowing for seamless addition or removal of instrumentation and direct configuration via a web-based interface. This allows scientists, rather than controls engineers, to add sensors relevant to their specific reaction and collect real time data for analysis.

Collaboration between Takeda and Zeton was integral to the project’s success. Takeda’s openness to sharing insights and techniques, coupled with Zeton’s manufacturing and engineering experience  proved invaluable in overcoming obstacles.

Looking forward, the project serves as a benchmark for the industry, aligning with the growing trend towards continuous manufacturing in pharmaceuticals. Plans for expansion include incorporating additional sub-modules for solvent exchanges and continuous distillation at a lab scale.

Working alongside Takeda Pharmaceuticals’ Laboratory group underscored the importance of effective collaboration and innovation. Their commitment to pushing boundaries and embracing new technologies highlights their position as pioneers in the pharmaceutical R&D landscape.

“Partnering with Zeton has been outstanding. Their innovative modular approach helped us revolutionize lab-scale unit operations. Zeton’s expertise and collaboration were key to overcoming challenges associated with compact designs while maintaining functionality and aesthetics. This project sets the foundation for our modularized process development in continuous manufacturing.” – Takeda Pharmaceuticals