Abstract
A process improvement in a tablet manufacturing process within a pharmaceutical industry was carried out based on an eco-efficiency approach. As it is one of the most energy consuming processes in the production line, the tablet manufacturing process was considered. It has the highest production volume with a complicated and long manufacturing product life cycle. Data were collected on energy inputs and emissions data for the stages of powder direct mixing, particle size reduction, and tableting. A straightforward approach was then used to analyze environmental impacts in terms of GHG emissions. Non- added value steps were removed from the product life cycle process, which has led to significant time and cost savings, as well as to a reduction in the emission. Annual economic savings have been achieved, a time reduction of approximately 71% was attained, and the reduction in GHG emissions and energy cost were 73.2%. The g CO2eq per tablet reduction has been calculated within the process improvement to be 2.06 g CO2eq per tablet instead of 7.71 g CO2eq per tablet.
Highlights
Tablets are currently among the most common oral solid dosage forms for drugs [1]
600 μm, μm, while while the the particle particle size size diameter diameter of of the the product product powder μm; there is no in this studystudy process to useto them, powder equals equalsor orisisless lessthan than μm; there is need no need in case this case process use because the homogeneity of the powder is not affected and the sifter is used instead of them
Pharmaceutical manufacturing industries needneed to employ innovation, cutting edgeedge scientific and and Pharmaceutical manufacturing industries to employ innovation, cutting scientific engineering knowledge, and the of quality management to respond to the challenges of engineering knowledge, andbest theprinciples best principles of quality management to respond to the challenges new of discoveries
Summary
Tablets are currently among the most common oral solid dosage forms for drugs [1]. The active pharmaceutical ingredient (API) molecule is the limiting factor in the development of an appropriate formulation; the manufacturing process for solid dosage forms varies from compound to compound.In the competitive environment of business, it is necessary for the compression operation to be efficient in terms of production cost [2,3,4]. Tablets are currently among the most common oral solid dosage forms for drugs [1]. The active pharmaceutical ingredient (API) molecule is the limiting factor in the development of an appropriate formulation; the manufacturing process for solid dosage forms varies from compound to compound. In the competitive environment of business, it is necessary for the compression operation to be efficient in terms of production cost [2,3,4]. Pharmaceutical manufacturing operations are inefficient and costly due to “self-imposed” constraints in the system that lead to low efficiency processes [4,5,6]. “Eco-efficiency” is a term that does not yet appear in dictionaries but has already gained considerable force in shaping the environmental policies and practices of leading corporations Variability in product quality is caused through insufficient process control; advanced control strategies can be employed to ensure consistent product quality [5,7,8,9].
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