MIT researchers have developed a compact, portable pharmaceutical manufacturing system that can be reconfigured to produce a variety of drugs on demand.
Just as an emergency generator supplies electricity to handle a power outage, this system could be rapidly deployed to produce drugs needed to handle an unexpected disease outbreak, or to prevent a drug shortage caused by a manufacturing plant shutdown, the researchers say.
“Think of this as the emergency backup for pharmaceutical manufacturing,” says Allan Myerson, an MIT professor of the practice in the Department of Chemical Engineering. “The purpose is not to replace traditional manufacturing; it’s to provide an alternative for these special situations.”
Such a system could also be used to produce small quantities of drugs needed for clinical trials or to treat rare diseases, says Klavs Jensen, the Warren K. Lewis Professor of Chemical Engineering at MIT.
“The goal of this project was to build a small-scale, portable unit that was completely integrated, so you could imagine being able to ship it anywhere. And as long as you had the right chemicals, you could make pharmaceuticals,” Jensen says.
Jensen, Myerson, and Timothy Jamison, the head of MIT’s Department of Chemistry, are the senior authors of a paper describing the new system in the March 31 online edition of Science. The lead author is MIT research associate Andrea Adamo.
More flexibility
Traditional drug manufacturing, also known as “batch processing,” can take weeks or months. Active pharmaceutical ingredients are synthesized in chemical manufacturing plants and then shipped to other sites to be converted into a form that can be given to patients, such as tablets, drug solutions, or suspensions. This system offers little flexibility to respond to surges in demand and is susceptible to severe disruption if one of the plants has to shut down.
Many pharmaceutical companies are now looking into developing an alternative approach known as flow processing — a continuous process that is done all in one location. Five years ago, an MIT team that included Jamison, Jensen, and Myerson demonstrated a larger prototype (24 by 8 by 8 feet) for the continuous integrated manufacturing of drugs from chemical synthesis to tablets. That project has ended, but the continuous manufacturing initiative, funded by Novartis, is still underway as the researchers develop new methods for synthesis, purification, and formulation.
In the new endeavor, funded by the Defense Advanced Research Projects Agency (DARPA), the MIT researchers built on what they learned from the Novartis-funded project to create a much smaller, transportable device. Their new system can produce four drugs formulated as solutions or suspensions — Benadryl, lidocaine, Valium, and Prozac. Using this apparatus, the researchers can manufacture about 1,000 doses of a given drug in 24 hours.
Key to the continuous system is the development of chemical reactions that can take place as the reactants flow through relatively small tubes as opposed to the huge vats in which most pharmaceutical reactions now take place. Traditional batch processing is limited by the difficulty of cooling these vats, but the flow system allows reactions that produce a great deal of heat to be run safely.
“In many cases we were developing syntheses of targets that had never been done in a continuous flow platform,” Jamison says. “That presents a lot of challenges even if there is a good precedent from the batch perspective. We also recognized it as an opportunity where, because of some of the phenomena that one can leverage in [a flow-based system], you can make molecules differently.”
Page 1 of 2
Suggested Items
Flexible Circuit Technologies Welcomes Regional Business Development Manager Derek Rossberg
07/15/2025 | Flexible Circuit TechnologiesFlexible Circuit Technologies a Minnesota-based flexible circuit and advanced electronics contract manufacturer, welcomes Derek Rossberg as Regional Business Development Manager.
Electronics Manufacturing & Assembly Collaborative (EMAC) Announces Innovative Student Competition
07/15/2025 | EMACThe Electronics Manufacturing & Assembly Collaborative (EMAC) recently announced the launch of the Bright Manufacturing Challenge 2025, a revolutionary hands-on competition that transforms how students experience electronics manufacturing and robotics engineering.
Delta Electronics Thailand Ranked Among Asia’s Top Corporates at the Alpha Southeast Asia 15th Institutional Investor Awards
07/14/2025 | Delta ElectronicsDelta Electronics (Thailand) Public Company Limited, a global leader in power management and smart green solutions, has been recognized by global investors for its excellence in investor relations and corporate governance, earning top ranking in the “Most Improved Investor Relations” at the Alpha Southeast Asia 15th Annual Institutional Investor Awards for Corporates, held on June 30, 2025, in Singapore.
Kimball Electronics' Pride Month Celebrations
07/14/2025 | Kimball ElectronicsAt Kimball Electronics, we believe in fostering a culture of inclusion, respect, and belonging. This June, our global teams came together to celebrate PRIDE Month with meaningful actions that reflect our commitment to the LGBTQ+ community.
NOTE Posts Interim Report for Q2 2025
07/14/2025 | NOTENOTE reports stable second-quarter results for 2025 with continued profitability and strong cash flow, reaffirming its growth strategy despite a challenging market environment.