Optimizing Pharmaceutical Manufacturing Efficiency

Pharmaceutical Technology® spoke with Luca Cavazzini, Sales & Marketing director at IMA Active, a division of IMA Pharma, at the company’s NEXTEN event, which was held in Lake Como, Italy in October 2025, to learn more about some of the challenges facing pharmaceutical manufacturers and how IMA Active addresses these challenges. IMA Active provides technologies for oral solid dose manufacturing, as well as integrated systems and services that help pharmaceutical companies accelerate time-to-market within a regulatory compliance environment.

PharmTech: In what ways is the drive for sustainability influencing facility design and equipment selection/upgrading?

Cavazzini (IMA Active): Sustainability has become a strategic pillar for pharmaceutical manufacturing, influencing not only facility layouts but also the way equipment is designed and implemented. At IMA Active, we see sustainability as a combination of efficiency, resilience, and compliance. This means integrating energy-efficient systems, compact footprints, modular design, and predictive maintenance to extend machine lifecycle and reduce resource consumption.

A clear example is DOMINA, our latest tablet press. It combines advanced control systems with real-time monitoring to minimize energy usage and scrap. Features like Energy Diary give manufacturers full visibility of consumption, enabling data-driven decisions for greener operations. Its modular architecture supports gradual investment and reduces downtime, while adaptive automation ensures consistent quality with minimal waste.

Ultimately, sustainability is not just operational, it’s strategic. By embedding these principles into our technology roadmap, we help pharmaceutical companies achieve environmental goals while maintaining productivity and regulatory alignment. This approach ensures long-term stability and a future-ready production model.

Which recent innovations in product development or process optimization have had the broadest impact on cost, quality, or speed-to-market in manufacturing operations?

At IMA Active, recent innovation has focused on continuous processes and specialized applications that deliver measurable benefits in efficiency and quality. Our Continuous Direct Compression (CDC) technology offers a lean and flexible tableting solution that, combined with PAT [process analytical technology] tools, enables rapid achievement of a state of control and eliminates waste during start-up and shutdown. Alongside CDC, our Continuous Coaters complete the range for high-throughput coating, ensuring consistent performance for large batches. In capsule filling, we have introduced dedicated solutions for dry powder inhalers (DPIs), meeting growing demand for respiratory therapies with precision and reliability.

The most transformative innovation is modularity. Modular tablet compression platforms deliver competitive advantages globally by enabling rapid format changes, scalability for gradual investment, and seamless integration with Pharma 4.0 concepts. They improve operational efficiency and sustainability while adapting to diverse market needs.

DOMINA embodies this vision. Its plug-and-play architecture, patented Dynamicam filling system, and adaptive automation ensure precision and flexibility. Combined with brushless motorization and servo-assisted changeovers, DOMINA minimizes downtime and maximizes quality, helping manufacturers cut costs, speed up production, and embrace the future of smart manufacturing.

What role do artificial intelligence (AI) and digital technologies play in improving manufacturing efficiency, and what are some unresolved barriers to full adoption?

AI and digitalization are transforming pharmaceutical manufacturing, and at IMA Active we apply them in a practical, process-driven way. Our machines integrate advanced algorithms for real-time optimization, predictive analytics, and preventive diagnostics. This enables automatic adjustment of production settings based on sensor data, while continuously monitoring operating conditions to detect anomalies early.

Digital technologies also enhance usability: guided interfaces and advanced diagnostics simplify operator decisions and reduce human error. These systems improve product quality, minimize waste, and increase process stability.

However, adoption faces critical challenges: balancing advanced automation with intuitive usability for operators, ensuring high-quality and integrated datasets, and meeting regulatory demands for explainable AI and data integrity. Cultural and skill gaps also persist, requiring robust training and change management.

What are the other biggest challenges that you see in your market that should be addressed in the coming year?

Pharmaceutical manufacturing faces a convergence of challenges that go beyond technology. Regulatory complexity is increasing, with global frameworks demanding stricter compliance and data integrity.

Supply chain resilience remains a priority, as companies work to strengthen continuity and flexibility in a dynamic global scenario, while sustainability and environmental transparency are becoming non-negotiable priorities. Digitalization introduces its own challenges: integrating legacy systems, ensuring cybersecurity, and balancing advanced automation with intuitive usability for operators. Finally, the growing need for specialized skills calls for continuous training and cultural transformation.

These challenges are not obstacles; they are catalysts for innovation. They push us to design smarter technologies, strengthen global service networks, and create solutions that combine flexibility, compliance, and sustainability. At IMA Active, we see this as an opportunity to lead the transition toward a more resilient and future-ready pharmaceutical ecosystem.

How are you addressing these?

We respond to market challenges with a comprehensive strategy that goes far beyond equipment supply. We deliver complete solutions, from standalone machines to fully integrated lines, combining engineering, automation, and software to meet the evolving needs of pharmaceutical manufacturers. Innovation and digitalization are at the core of our roadmap: we embed Pharma 5.0 principles into every technology, leveraging real-time monitoring, predictive analytics, and digital twins to optimize processes, reduce downtime, and ensure data integrity. Continuous manufacturing reflects our commitment to future-ready production models.

Equally important is our global support network and Competence Centers, which accelerate innovation through trials, scale-up, and process optimization, while providing training and lifecycle assistance to guarantee operational continuity. Sustainability also drives our vision: energy-efficient systems, modular architectures, and intelligent control features minimize waste and environmental impact while adapting to diverse regional requirements.

By integrating technology, digital transformation, and service excellence, we help pharmaceutical companies turn complexity into opportunity, building efficient, compliant, and sustainable production ecosystems worldwide.

About the interviewee

Luca Cavazzini is Sales & Marketing Director at IMA Active, a division of IMA Pharma, who's mission is to deliver advanced technologies for oral solid dose manufacturing, combining mechanical excellence with digital innovation. Luca's role focuses on aligning market needs with our technological roadmap, developing solutions that anticipate regulatory, operational, and sustainability challenges. Beyond machines, the company aims to provide integrated systems and services that help pharmaceutical companies accelerate time-to-market while ensuring quality and compliance.