H-CCAT · Project

Reusable Solid Catalysts That Cut Costs in Pharmaceutical Drug Production

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Making drugs like HIV medication requires expensive chemical reactions where the catalyst — think of it as the spark plug — gets used once and thrown away. H-CCAT built solid, reusable catalysts that can be recovered and used again and again, like switching from disposable batteries to rechargeables. They scaled these up to kilogram quantities and tested them at a Johnson & Johnson minipilot plant in Belgium. The target: cheaper, cleaner production of key building blocks found in medicines for HIV, cancer, and influenza.

By the numbers

consortium partners

countries represented

industrial partners in consortium

36%

industry participation ratio

total project deliverables

demo-stage deliverables completed

The business problem

What needed solving

Pharmaceutical companies spend heavily on catalysts that can only be used once and then discarded, driving up the cost of producing drug ingredients. These homogeneous catalysts also contaminate products with metal residues, requiring expensive purification steps. The industry needs recoverable, high-performance catalysts that work reliably at production scale without leaching metals into the final product.

The solution

What was built

The project delivered first-generation palladium-functionalized hybrid silica catalysts for direct C-H arylation and palladium-functionalized redox metal-organic framework catalysts for oxidative coupling. These were scaled to kilogram production and demonstrated at minipilot scale at a J&J facility in Belgium, with flow reactor protocols and spray-drying shaping methods developed for industrial use.

Audience

Who needs this

Pharmaceutical companies producing active pharmaceutical ingredients (APIs)Fine chemical manufacturers doing palladium-catalyzed C-H functionalizationContract development and manufacturing organizations (CDMOs)Catalyst suppliers serving the pharma and specialty chemicals sectorsGreen chemistry consultancies advising on waste reduction in chemical production

Business applications

Who can put this to work

Pharmaceutical Manufacturing

enterprise

Target: Drug manufacturers producing active pharmaceutical ingredients (APIs)

If you are a pharma manufacturer dealing with high catalyst costs and waste in producing arylated drug intermediates — this project developed solid, recoverable catalysts scaled to kg quantities and demonstrated at minipilot scale at a J&J facility. These catalysts offer higher turnover numbers and better selectivity than traditional one-use catalysts, directly reducing raw material costs and solvent waste in API production.

Fine Chemicals

mid-size

Target: Specialty chemical companies producing aromatic intermediates

If you are a fine chemicals producer struggling with expensive palladium catalyst losses and poor atom economy in C-H functionalization reactions — this project created hybrid silica and metal-organic framework catalysts that prevent metal leaching through strong metal-ligand bonds. The flow reactor protocols maximize catalyst lifetime, meaning less palladium wasted per batch of product.

Contract Research & Manufacturing (CDMO)

any

Target: Contract manufacturers offering custom synthesis services

If you are a CDMO looking for competitive advantages in producing pharmaceutical building blocks — this project delivered catalysts produced via efficient one-step protocols that minimize solvent use and waste. The spray-drying shaping methods preserve catalyst performance at scale, and the demonstrated flow chemistry approach could differentiate your process offering for clients needing arylated or alkenylated aromatics.

Frequently asked

Quick answers

What would it cost to adopt these catalysts in our production line?

The project does not disclose specific catalyst pricing. However, the catalysts are designed for high recoverability and turnover numbers exceeding current homogeneous catalysts, which means the cost-per-reaction-cycle drops significantly. The one-step synthesis protocols and minimized solvent use also reduce production costs for the catalysts themselves.

Can these catalysts work at industrial production volumes?

Catalyst synthesis was scaled to kilogram quantities, and a minipilot demonstration was conducted at the Johnson & Johnson site in Belgium. The project also developed flow reactor protocols and spray-drying shaping methods specifically designed for industrial-scale operation. Moving from minipilot to full production scale would require further engineering.

How does IP and licensing work for these catalysts?

Based on available project data, the consortium includes 11 partners across 6 countries with 4 industrial partners. IP generated during the project would be governed by the Horizon 2020 grant agreement. Interested companies should contact the coordinator at KU Leuven to discuss licensing terms for the hybrid catalyst technologies.

Which specific drugs or molecules can these catalysts produce?

The catalysts target arylated and alkenylated aromatics that serve as building blocks for active pharmaceutical ingredients. The specific case study mentioned is Rilpivirine, an HIV medication. The project also references molecules relevant to influenza and cancer treatment.

How do these catalysts compare to what we use today?

Current industrial practice relies on homogeneous (dissolved) catalysts that cannot be recovered and reused. H-CCAT's solid catalysts offer better recoverability, higher turnover numbers, and better selectivity. Metal leaching is prevented by strong bonds between metals and embedded ligands, solving a major contamination problem in pharmaceutical production.

What is the timeline to get these catalysts into our facility?

The project ran from 2017 to 2021 and completed minipilot demonstrations. A techno-economic assessment and business plan were part of the project deliverables. Based on the minipilot stage reached, additional scale-up and regulatory qualification work would be needed before full commercial deployment.

Consortium

Who built it

The H-CCAT consortium of 11 partners across 6 countries (Belgium, Germany, France, Italy, Norway, UK) is well-balanced for technology transfer, with 4 industrial partners representing 36% of the group alongside 4 universities and 3 research organizations. The presence of Johnson & Johnson as a demonstration site host signals strong pharmaceutical industry pull. With only 1 SME, the consortium leans toward large-scale industrial deployment rather than startup commercialization. The coordinator, KU Leuven, is a top European research university with strong industry collaboration track record.

KATHOLIEKE UNIVERSITEIT LEUVENCoordinator · BE
AXEL'ONEparticipant · FR
UNIVERSITE DE MONTPELLIERthirdparty · FR
GEORG-AUGUST-UNIVERSITAT GOTTINGEN STIFTUNG OFFENTLICHEN RECHTSparticipant · DE
SIKEMIAparticipant · FR
UNIVERSITA DEGLI STUDI DI PERUGIAparticipant · IT
CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE CNRSparticipant · FR
JOHNSON MATTHEY PLCparticipant · UK
JANSSEN PHARMACEUTICA NVparticipant · BE

How to reach the team

Coordinator is at KU Leuven (Belgium). SciTransfer can facilitate a direct introduction to the research team.

Order a report on this consortium See KATHOLIEKE UNIVERSITEIT LEUVEN profile →

Next steps

Talk to the team behind this work.

Want to explore licensing these catalyst technologies for your production line? SciTransfer connects you directly with the H-CCAT team — contact us for a tailored briefing.

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