CSTR vs PFR in pharma industry

By apoorvkumaar07 | Updated: May 11, 2025, 12:11 a.m.

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CSTR vs PFR in the pharmaceutical industry
A complete comparison 
CLL 122 Motion video 
WHAT IS A 
    Continously Stirred Reactor
(CSTR)
 
A kind of reactor where reactants enter continuously (inlet), products exit continuously (outlet), and continuous stirring ensures a uniform concentration throughout the reactor. 
WHAT IS A 
PLUG FLOW REACTOR
(PFR)
 
A plug flow reactor (PFR), also known as a tubular reactor, is a continuous flow reactor where reactants enter one end and travel through a tube or pipe, undergoing chemical reactions as they move toward the outlet
Let's compare CSTR vs PFR 
Criteria
Mixing                              Perfect mixing                  No back mixing 
CSTR
PFR
Residence Time         Broad Distribution       Narrow distribution
Conversion                  
Lower for same volume         Higher for same volume 
Scalability                    Easier (modular)           Complex
Sterility                        Simpler with CIP/SIP       Careful design
What is API in Pharmacy ?
In pharmaceuticals, API stands for Active Pharmaceutical Ingredient. It's the biologically active substance in a drug that produces the intended therapeutic effect.
Role of CSTR and PFR in making API

Reactors are the heart of API manufacturing. They provide the controlled environment (temperature, pressure, mixing, and residence time) where raw materials (reactants) undergo chemical transformation into desired intermediates and final APIs.
Let's talk about CSTR 
Advantages                     Disadvantages        
Ideal for exothermic reactions

Steady Operations

Easy to scale by numbering up 
Lower conversion per unit volume

Back-Mixing reduces selectivity when side reactions are present 
In the case of PFR, 
Advantages                      Disadvantages 
High conversion and selectivity

Less Back-Mixing

Efficient use of Reactants 
Harder to control temperature

Can have Hot Spots may require heat exchanger 
In conclusion
Use CSTR when you want,

Flexibility Control Compliance

Use PFR when you want,

1. Large scale production 
2. High efficiency production 
Thank You.

CSTR vs PFR in pharma industry

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