Abstract
Following the paradigm shift in the pharmaceutical industry from batch to continuous production, additional instrumentation and revision of control strategies to optimize material flow throughout the downstream processes are required. Tableting manufacturing is one of the most productive in terms of turnover and investment into new sensor technologies is an important decision-making step. This paper proposes a continuous solution to detect changes in material properties, and a control algorithm to aid in minimizing risk at the end-product line. Some of the sub-processes involved in tableting manufacturing perform changes in powder and liquid mixtures, granulation, density, therefore changing flow conditions of the raw material. Using impedance spectroscopy in a continuous sensing and monitoring context, it is possible to perform online identification of generalized (fractional) order parametric models where the coefficients are correlated to changes in material properties. The model parameters are then included in a self-tuning control gain used in ratio control as part of the local process control loop. The solution proposed here is easy to implement and poses a significant added value to the current state of art in pharmaceutical manufacturing technologies.
Highlights
A core challenge of Industry 4.0 is the demand for versatile manufacturing that can cope with material availability and variability, which is relevant to the field of personalized medicine goals [1]
We have investigated a new approach for material properties analysis in the pharmaceutical industry using impedance spectroscopy sensing
The results indicate the potential of the proposed methodology for self-tuning ratio control, where the model parameters obtained using impedance spectroscopy will be used for the self-tuning control gain
Summary
A core challenge of Industry 4.0 is the demand for versatile manufacturing that can cope with material availability and variability, which is relevant to the field of personalized medicine goals [1]. Recent advances in technology and instrumentation have pushed forward the transition from batch to continuous process control in the pharmaceutical industry [2,3]. One of the main advantages of continuous manufacturing is that it enables demand-driven scaling of production volume and product specifications. Impedance spectroscopy is a powerful instrument with significant added value in optimizing control of manufacturing industries [4,5]. The tableting industry has the highest production volume and changes in the manufacturing process have a significant impact on the overall production costs. The gold standard in pharmaceutical manufacturing of oral solid dosage forms is still batch-wise creativecommons.org/licenses/by/
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