Apart from non-potent compounds, Laurus boasts one of the largest capacities for handling potent, Hi-Potent compounds—those with OEL between 1-10ug/m³ TWA8Hrs. This capability allows the manufacturing of potent and high-potent moieties such as oncology drugs and hormonal ingredients in complete isolation, ensuring occupational safety while maintaining economical production, with batch sizes reaching up to 250kg.

While Laurus Labs prioritizes innovative chemistry and intelligent process development to avoid separations at scale, we recognize that regulatory constraints can sometimes hinder rapid process changes. Hence, possessing the capability to handle separations at scale becomes a significant value-add, especially when dealing with critical client-transferred projects. Here's a snapshot of our separation and resolution capabilities at scale:

Conventional column chromatography (Normal phase) Preparatory column chromatography (reverse-phase) for potent separations Simulated Moving Bed (SMB) also known as Multi-Column Chromatography (MCC) using Novasep Varicol technology Ultrafiltration systems from Sartorius Stedim

In recent years, Laurus Labs has progressively enhanced its capabilities in flow chemistry at scale. This complements continuous-flow chemistry (CFC) processes developed in our R&D facilities for both our portfolio products and client projects. Our current ability to handle flow chemical processes at scale includes Gas-Liquid and Liquid-Liquid processes involving solid catalysts. The listed installations below represent our commitment to advancing flow chemistry:

Micro Channels:  Corning G4 for commercial-scale operations
Plug Flow Reactors: Technoforce PE 800
The plug-flow reactors seamlessly scale up to the PFRs installed in our manufacturing facility, ensuring efficient and effective processes. Looking ahead, we anticipate expanding our capacities for flow processes involving precious metal catalysts, incorporating fixed-bed reactors.

In alignment with emerging trends in pharmaceutical manufacturing, Laurus Labs made early investments in dedicated capacities for handling bio-catalytic processes. Our state-of-the-art infrastructure includes large-volume reactors, some with capacities up to 20KL. These capabilities enable us to optimize batch sizes, reaching up to 750kg output and beyond where feasible. The investment in bio-catalysis aligns with our commitment to staying at the forefront of innovative and sustainable manufacturing practices in the pharmaceutical industry.

Laurus Labs boasts multiple sites equipped to handle High-Energy & Hazardous Reactions, including processes like Grignard synthesis, metal halides reactions, and high-pressure hydrogenation. Our hydrogenation capabilities encompass vessel capacities ranging from 100L to 6KL, with the ability to handle pressures up to 50 bar. Moreover, Laurus is adept at managing temperature conditions ranging between -80°C (-112°F) to 250°C (480°F) across multiple sites. These capabilities underscore our commitment to safety, efficiency, and excellence in handling complex chemical processes.

As a fully integrated pharmaceutical manufacturer, Laurus Labs ensures the flexibility to alter particle sizes of drug substances to meet diverse formulation requirements. Our robust infrastructure includes large-volume capacities for various particle-size alteration equipment, such as the Air Jet Mill (Micronizer) for both potent and non-potent molecules, Multi-mill, Pulverizer, Pin Mill, Co-mill, Ultrafine Mill, IKA Inline Colloidal Mill (wet milling), and more. With hourly capacities ranging from 2kg to 400kg per hour, we consistently meet the demands of diverse projects. These capabilities exemplify our commitment to providing comprehensive solutions and maintaining high-quality standards in pharmaceutical manufacturing.