Multi-Criteria Assessment of Continuous Manufacturing Reactor Technologies in Upstream Pharmaceutical Supply Chains

The COVID-19 pandemic highlighted vulnerabilities in upstream pharmaceutical supply chains (PSC) associated with the manufacture of essential active pharmaceutical ingredients (APIs). The need to develop health countermeasures provided new impetus to supporting advanced manufacturing technologies such as process intensification through continuous manufacturing (CM). Recent advanced manufacturing developments suggest potential advantages in adopting CM over traditional batch technologies. However, at an early stage of evaluation detailed quantitative information is limited, and selecting specific reactor technologies based on multiple, conflicting criteria is challenging. To address these early-stage manufacturing technology selection challenges, this paper applies an Analytical Hierarchy Process approach, integrating multiple managerial and engineering criteria. The analysis focuses on reactor technologies in upstream PSC manufacturing. Findings suggest that microreactor technologies outperform alternatives all things considered. However, PSC managerial considerations introduce nuances in specific therapeutic areas e.g., antivirals where a tension between complex chemistry and the need for flexibility in unit operations may favour batch manufacturing. For analgesics the need to exploit the existing manufacturing base whilst addressing inventory reduction favour technologies that incorporate elements of batch and CM. Research enriches previous conceptual frameworks predicated on volume-variety considerations, providing an empirical workflow for the multi-faceted evaluation of alternative CM reactor technologies in PSC.