Inlet HEPA filter and top of GEA PSD-3 drying chamber.
The PSD-3 spray dryer is tailored for handling highly potent pharmaceutical products classified as OEB-5, which have occupational exposure limits in the nanogram per cubic meter range. This makes it one of the most advanced systems for high-containment spray drying in the pharmaceutical industry. Developed in partnership with JGC Japan Corporation, the dryer integrates advanced containment, precise process control, and modern automation to meet stringent safety and operational standards.
Dr. David Costes, Area Sales Manager at GEA, stated: “This pharmaceutical spray dryer is one of the most technically advanced spray drying systems ever built by GEA. Our team’s extensive expertise in spray drying, combined with JGC’s engineering excellence and Chugai’s deep knowledge of high-containment processes, has allowed us to create a truly groundbreaking solution.” GEA’s 30 years of experience in pharmaceutical spray drying underpins this achievement, setting new benchmarks for the industry.
The project required innovative solutions to meet Chugai’s and JGC’s rigorous requirements for containment and automation. Jesper Hansen, Senior Process Technologist at GEA, noted: “This project has been a great learning experience for us. Working alongside such detail-oriented and perfection-driven partners like Chugai and JGC pushed us to go beyond conventional limits.” The customized solutions ensure the dryer meets the specific needs of OEB-5 product processing.
A member of Chugai’s FJ3 project team commented: “We are thrilled to have successfully completed this project and to have the new spray dryer now in full production. It significantly enhances our drying capabilities, offering greater flexibility and efficiency for our operations.” They added: “GEA’s creativity and technical know-how were key to delivering a solution that met all our specific requirements. We are confident that this new spray dryer will play a crucial role in advancing Chugai’s product development and manufacturing capabilities.”
The collaboration enhances Chugai’s ability to produce innovative medicines at its Fujieda facility. The PSD-3 dryer supports efficient and safe production, contributing to Chugai’s mission to advance pharmaceutical development. This project showcases the combined expertise of GEA, Chugai, and JGC, establishing a new standard for high-containment pharmaceutical manufacturing in Japan.
