In this podcast, we spoke with Nainesh Shah, Sr. Application Engineer, Asahi Kasei Bioprocess America, about how inline buffer formulation and their MOTIV^® system offers a more efficient, scalable, and cost-effective approach to buffer preparation. Traditional methods require large storage spaces, pose risks of leakage, and create inefficiencies that can disrupt production. In contrast, inline buffer formulation enables real-time mixing of concentrated ingredients, eliminating storage constraints and allowing for dynamic adjustments based on demand. With benefits like reduced waste, lower costs, and improved regulatory compliance, this technology is streamlining operations while ensuring precision and adaptability. As the industry shifts toward smarter manufacturing solutions, inline buffer formulation is paving the way for the future of pharmaceutical production.

How Inline Buffer Formulation is Changing the Industry

Nainesh, who has over 40 years in the pharmaceutical industry and six years at Asahi Kasei, highlights the evolution of buffer preparation. “Traditionally, buffer dilution involved a concentrate formulated in advance, which was then diluted with water to achieve the desired solution.”

Modern inline buffer formulation transforms this process by enabling real-time mixing of individual components. “Instead of storing pre-made buffer solutions, MOTIV allows for real-time formulation using individual components. The system precisely combines these ingredients on demand, ensuring accuracy and eliminating storage-related inefficiencies,” Shah explains.

Enhanced Efficiency, Cost Savings, and Waste Reduction

The advantages of MOTIV extend beyond storage and formulation flexibility. “With traditional methods, production can be delayed if pre-made buffers aren’t readily available. If a change in concentration or formulation is required, additional time is needed for sourcing and preparation,” Shah notes. “With MOTIV, you can use a single concentrated solution to create multiple buffer variants by adjusting the dilution ratio. This eliminates the need for multiple pre-concentrated stocks, reducing storage space, waste and increasing efficiency.”

Cost efficiency is another crucial factor. “Return on investment (ROI) depends on whether the facility has an existing buffer preparation setup or is installing a fresh system. For existing setups, ROI typically takes around two years due to transition considerations. However, for new installations, ROI can be achieved within 1.5 years,” Shah states. He adds that Asahi Kasei provides an easy-to-use ROI calculator to help companies assess their financial benefits.

Additionally, inline buffer formulation improves sustainability by minimizing waste and reducing the environmental impact of excess buffer storage. By eliminating the need for large buffer stockpiles, facilities can lower their material costs and optimize resource utilization.

Scalability and Customization for Diverse Production Needs

One of the standout advantages of the MOTIV inline buffer formulation system is its scalability. “Our smallest system supports up to 1,200 liters per hour with three inlets—one for water and two for concentrates like acid, base, or salt solutions. On the higher end, we can scale up to 5,000 or even 12,000 liters per hour, completely customizable with multiple inlets based on customer requirements,” says Shah.

This flexibility is particularly valuable for pharmaceutical manufacturers with varying production demands. Facilities producing multiple types of buffers can benefit from the system’s adaptability, allowing them to switch formulations with minimal downtime. Instead of maintaining separate storage tanks for different buffer types, inline buffer formulation enables dynamic adjustments based on real-time requirements.

Addressing Complex Formulations and Space Constraints

MOTIV is particularly beneficial for high-volume buffer requirements and complex formulations. “As pharmaceutical processes advance, buffers require multiple ingredients, not just simple acid-base-salt combinations. MOTIV automates these complex formulations with precision, ensuring consistency while reducing human error,” says Shah.

Moreover, these systems help optimize space usage. Traditional buffer preparation requires large storage tanks, which can be a logistical challenge for facilities with limited space. By replacing bulky storage units with a compact inline formulation system, pharmaceutical companies can free up valuable floor space for other critical operations, leading to improved overall facility efficiency.

Streamlining Global Operations and Regulatory Compliance

MOTIV enables pharmaceutical companies to streamline global operations. “A single facility’s buffer formulation data can be easily transferred to other locations, reducing the need for redundant validation and documentation. This simplifies global production expansion while maintaining quality and compliance,” says Shah.

The ability to standardize buffer preparation across multiple facilities also aids in regulatory compliance. Pharmaceutical companies must adhere to stringent guidelines set by agencies such as the FDA and EMA. Inline buffer formulation ensures consistent production parameters, reducing variability and ensuring that each batch meets regulatory standards. By integrating real-time monitoring and control systems, manufacturers can also enhance traceability and data integrity, which are essential for compliance.

Overcoming Misconceptions and Ensuring Adaptability

Shah also addresses common misconceptions about inline buffer formulation. “Some worry that once the system is set up for a specific product, it can’t accommodate new formulations. However, as long as the flow capacity and analytical requirements remain compatible, new buffers can be integrated seamlessly. Even additional analytical technologies can be incorporated if planned ahead.”

Another concern among industry professionals is whether inline buffer formulation can maintain the same level of accuracy as traditional methods. Shah assures that modern inline systems are equipped with precise monitoring technology to ensure consistency. Real-time adjustments can be made to maintain optimal formulation parameters, eliminating the risk of deviations.

The Future of Buffer Preparation: Embracing Innovation

Asahi Kasei’s MOTIV system is setting a new standard in buffer preparation. As pharmaceutical manufacturing continues to evolve, adopting innovative solutions like inline buffer formulation is becoming essential. By offering flexibility, cost savings, and process optimization, inline buffer formulation provides a robust solution for modern pharmaceutical production.

“The industry is shifting towards efficiency and adaptability. With advanced inline buffer formulation, companies can future-proof their operations while ensuring consistent quality and regulatory compliance,” Shah concludes.

In an era where precision and efficiency are paramount, inline buffer formulation stands out as a transformative technology. As industries evolve, solutions like these ensure that production remains agile, scalable, and ready to meet the demands of the future.

Upgrade to Better Buffer Management: Inline Buffer Formulation Systems | MOTIV^®