Abstract

Market globalisation, shortened patent lifetimes and the ongoing shift towards personalised medicines exert unprecedented pressure on the pharmaceutical industry. In the push for continuous pharmaceutical manufacturing, processes need to be shown to be agile and robust enough to handle variations with respect to product demands and operating conditions. In this paper we examine the use of operational envelopes to study the trade-off between the design and operational flexibility of the fluid bed dryer at the heart of a tablet manufacturing process. The operating flexibility of this unit is key to the flexibility of the full process and its supply chain. The methodology shows that for the fluid bed dryer case study there is significant effect on flexibility of the process at different drying times with the optimal obtained at 700 s. The flexibility is not affected by the change in volumetric flowrate, but only by the change in temperature. Here the method used a black box model to show how it could be done without access to the full model equation set, as this often needs to be the case in commercial settings.

Highlights

  • The power of big data, emanating from the process and from customers, is having a number of effects on manufacturing

  • Industry is going through something of a revolution to realise these aims. It is known as Smart Manufacturing, Industry 4.0 or Digitalisation because of the capabilities enabled by greater computing power, smarter algorithms, better measurement, and wider connectivity

  • We have presented for exploring operational flexibility for a fluid bed the heart of formulation processes for tablet

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Summary

Introduction

The power of big data, emanating from the process and from customers, is having a number of effects on manufacturing. With coordinated access to reliable data, a manufacturer can respond more rapidly and efficiently to supply chain demands. With data comes the capability and often the demands from internal and external stakeholders (customers, shareholders, regulators, neighbours, etc.) for greater transparency of operations. Industry is going through something of a revolution to realise these aims. It is known as Smart Manufacturing, Industry 4.0 or Digitalisation because of the capabilities enabled by greater computing power, smarter algorithms, better measurement, and wider connectivity. The smart manufacturing revolution is said to have three phases [1,2]: Factory and enterprise integration and plant-wide optimisation, Exploiting manufacturing intelligence, Creating disruptive business models

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