Innovative processes from Saltigo for optimized custom synthesis

Mumbai, Maharashtra, IND, 2009-10-09 19:41:18 (IndiaPRwire.com)


Saltigo's portfolio of organochemical custom syntheses for the entire life cycle of active pharmaceutical ingredients will take center stage on the company's stand at the CPhI 2009, which will be held in Madrid, Spain, from October 13–15. Saltigo, a wholly owned subsidiary of the LANXESS specialty chemicals group, will present its comprehensive range of services connected with the synthesis of active pharmaceutical ingredients.

There is much more to custom manufacturing than the reliable and timely delivery of the synthesized substances to the customer. A comprehensive portfolio of technologies and apparatus plus compliance in HSEQ (Health, Safety, Environment, Quality) are nowadays essential prerequisites for a custom manufacturer to operate successfully. Key aspects include the informed choice of synthesis routes and methods of process development and optimization. This expertise not only enables the traditional aspects such as yield, product quality and reaction times to be optimized, it is also becoming increasingly valuable when it comes to minimizing waste and energy consumption, for which reactions have to be selected that are attractive not only economically, but also ecologically.

One example is the solvent-free synthesis of a carboxylic acid chloride, which Saltigo uses for a precursor for a pharma compound. The output from a batch produced with this process is virtually 100 percent, because for every 100 metric tons of product, less than 500 kilograms of solid or liquid waste that require disposal are left over – just 0.5 percent. The process is noted for its inexpensive reagent, simple reaction control, low volume of solid waste, waste gases that can partly serve as a raw material, and minimal energy consumption. It is used by Saltigo, wherever possible, as the standard process for the production of chlorinations of other aromatic carboxylic acids.

Another example is the tailor-made oxidation of a complex alcohol by means of the modified Swern reaction, also for an active pharmaceutical ingredient. Unlike the traditional variant with oxalyl chloride/dimethyl sulfoxide, which produces a waste gas mixture of carbon monoxide, carbon dioxide and dimethyl sulfide, an alternative reagent mixture was chosen that forms only a single volatile waste gas product. Apart from using different chemicals, it has the important advantage that the process is run in a closed system and there is no need for any concept for disposal. It ensures that, even in the immediate vicinity of the plant, there are no unpleasant odors, either for the employees or for nearby residents.

“Challenging chemistries” help to manufacture products with a high yield and high level of purity. They also avoid the generation of waste and consequently cut production costs. Examples of such “challenging chemistries” include reactions with phosgene, fluorine compounds and organometallic reagents such as Grignard or organolithium compounds. While these reactions may involve the handling of hazardous substances and although safe operation of highly exothermal processes calls for a great deal of experience – and often special equipment, too – such reactions are frequently superior to all alternatives in terms of cost, time, and waste generation.

Compliance with CGMP standards at every scale with safe and flexible productions is a matter of course for Saltigo. The company's innovative custom synthesis therefore comes as a service package, which, depending on the customer's wishes, can extend from synthesis design, through process development and process optimization, to support in registration and licensing. Particularly at the present time, where the focus is on cash management, lower budgets and optimized inventory management, Saltigo has shown the true value of its expertise as a custom manufacturer. Permanent process improvements, cost reductions and innovative commercial solutions in all areas of product life cycle management now generate the added value for Saltigo's customers.

At the CPhI ShowCase, Dr. Christoph Schaffrath, Business Manager in Saltigo's Pharma business line, will present an overview of the areas of competence and the service portfolio of the company and its German production facilities in Leverkusen and Dormagen under the title “Our expertise, your API solution”. In conjunction with the capacities created for Saltigo by LANXESS Corp. in Redmond in the U.S. State of Washington for pre-clinical and early clinical phases, Saltigo is well equipped to satisfy the outsourcing requirements for the entire life cycle of active ingredient research and production and to carry out projects in all development phases along with commercialization.

Saltigo GmbH is a leading supplier in the field of custom synthesis, offering complete, tailor-made solutions for customers both in the crop protection and pharmaceuticals segments and in various non-life-science industries. The company is part of the LANXESS AG specialty chemicals group and belongs to the Advanced Intermediates segment, which generated sales of EUR 1,310 million in fiscal 2008. Saltigo, headquartered in Langenfeld with production facilities in Leverkusen and Dormagen, employs around 1,400 staff worldwide. LANXESS Corporation operates a site for Saltigo in Redmond (Washington, United States).

Detailed information about the company can be found on the internet at http://www.saltigo.com/.

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LANXESS is a leading specialty chemicals company with sales of EUR 6.58 billion in 2008 and currently 14,335 employees in 23 countries. The company is represented at 46 production sites worldwide. The core business of LANXESS is the development, manufacturing and marketing of plastics, rubber, intermediates and specialty chemicals.

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Leverkusen October 9, 2009.

bol (2009-00180e)

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This news release may contain forward-looking statements based on current assumptions and forecasts made by LANXESS AG management. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.