From Storage Tanks to Smart Systems: The Evolution of Buffer Preparation

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 c