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Real-Time Quality Control Real-Time Quality Control

► Real-Time API and excipient monitoring

►21 CFR Part 11 compliant software

► Hazardous and non-hazardous area solutions

► Flexible sample interfaces for powders, liquids, gels, pastes, and gases

You are responsible for product quality, process efficiency, and compliance. We help make pharmaceutical process monitoring simpler.
Control Southern and Nova Industrial Analytics bring laboratory-grade analytical capability directly to the production floor with real-time spectral sensing designed to help pharmaceutical manufacturers verify quality, optimize cleaning protocols, streamline workflows, and maintain regulatory compliance.

The Problem

Pharmaceutical manufacturers need better visibility into product quality, cleaning effectiveness, blend uniformity, drying end points, and water addition, without relying only on delayed off-line testing and manual sampling.

The Plan

Use real-time spectroscopy to monitor critical process and quality attributes directly in the process, then connect those measurements to your control and quality workflows.

Avoid Failure

Sampling variability, delayed lab results, over-drying, blend segregation, over-granulation, under- or over-dilution, and unnecessary cleaning cycles can create hold time, waste, rework, and compliance risk.

Achieve Success

Real-time visibility helps accelerate release decisions, reduce waste, shorten cleaning and drying cycles, improve batch consistency, and support compliant, process-based decision-making.
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Easy 3 Step Plan

Easy 3 Step Plan

1. Assess
Identify high-impact measurement points across cleaning, blending, dilution, drying, tablet compression, or granulation. 
2. Integrate
Design a solution tailored to your equipment and specifications, then connect it with your existing DCS/SCADA infrastructure and software environment. 
3. Operate with confidence
Train your team for confident operation and use continuous measurement, compliant software, and ongoing technical support to sustain performance.

Outcomes You Can Expect

  • Real-time visibility into API, excipient, moisture, and process condition changes. 
  • Faster decisions for vessel release, blend verification, drying end points, and tablet compression quality. 
  • Reduced lab testing, cleaning time, solvent use, hold time, and rework. 
  • Earlier detection of out-of-spec conditions to help prevent defective product and batch loss..

Simplified Installation & Operation

  • Hazardous and non-hazardous area solutions available for a wide range of pharmaceutical environments. 
  • IECEx certified options for hazardous areas.
  • Flexible, interchangeable sample interfaces for multiple product forms and operations. 
  • Seamless integration with DCS/SCADA systems plus compliant software and on-board chemometric model processing.

Pharmaceutical Applications

Measure residual active pharmaceutical ingredients directly in vessels and piping to support vessel release, reduce unnecessary cleaning cycles, and optimize both water-based and solvent-based cleaning protocols. This can reduce cleaning times by 20 to 30% and solvent consumption by up to 25%*
Monitor API and excipient distribution in continuous blending skids with real-time, inline measurement. Eliminate manual grab sampling variability, confirm blend uniformity in seconds instead of hours, and improve batch-to-batch consistency
Use closed-loop monitoring of water-for-injection during dilution to help hit label dose targets, reduce waste of high-value products, and maintain a sterile, automated verification environment.
Verify blend uniformity at the hopper or feed frame immediately prior to compression, detect segregation during transfer, and stop production if out-of-spec blend is detected before defective tablets are pressed.
Replace off-line loss on drying checks with continuous in-bed spectroscopy, improve drying accuracy, and stop drying at the exact specification point. This can reduce drying time by 15 to 20% while improving product stability and lowering energy costs*.
Monitor real-time water content, observe the transition from free to bound water, prevent over-granulation, and reduce material waste and rework through better process control.
*Measurable impact and outcome estimates provided by Nova Industrial Analytics. All information is subject to change without notice.