A Validated Model for Design and Evaluation of Control Architectures for a Continuous Tablet Compaction Process

Barros, Fernando Nunes de; Bhaskar, Aparajith; Singh, Ravendra

doi:10.3390/pr5040076

Cited by 8 publications

(3 citation statements)

References 32 publications

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“…In this context, information about the residence time distribution (RTD) of the material is crucial as it defines the flow and spreading of material within the manufacturing line. It can be applied to define batch and lot (which can be a batch or a specified portion of a batch) as the basis for material diversion (out-of-spec removal) and recall decisions, and is required to create a control strategy of a continuous process (Almaya et al, 2017b;Engisch and Muzzio, 2015b;Nunes de Barros et al, 2017;Su et al, 2017).…”

Section: Introductionmentioning

confidence: 99%

RTD-based material tracking in a fully-continuous dry granulation tableting line

Martinetz

Karttunen

Sacher

et al. 2018

International Journal of Pharmaceutics

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Continuous manufacturing (CM) offers quality and cost-effectiveness benefits over currently dominating batch processing. One challenge that needs to be addressed when implementing CM is traceability of materials through the process, which is needed for the batch/lot definition and control strategy. In this work the residence time distributions (RTD) of single unit operations (blender, roller compactor and tablet press) of a continuous dry granulation tableting line were captured with NIR based methods at selected mass flow rates to create training data. RTD models for continuous operated unit operations and the entire line were developed based on transfer functions. For semi-continuously operated bucket conveyor and pneumatic transport an assumption based the operation frequency was used. For validation of the parametrized process model, a pre-defined API step change and its propagation through the manufacturing line was computed and compared to multi-scale experimental runs conducted with the fully assembled continuous operated manufacturing line. This novel approach showed a very good prediction power at the selected mass flow rates for a complete continuous dry granulation line. Furthermore, it shows and proves the capabilities of process simulation as a tool to support development and control of pharmaceutical manufacturing processes.

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Section: Introductionmentioning

confidence: 99%

RTD-based material tracking in a fully-continuous dry granulation tableting line

Martinetz

Karttunen

Sacher

et al. 2018

International Journal of Pharmaceutics

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“…Finally, the matrix was removed, and the simulation process ended after waiting for 0.05 s. Although in real applications the punch remains at its lower position during a dwell time, this aspect was not simulated in order to reduce the computational costs. By using an appropriate dwell time, some of the defects in the compacts are reduced [31,32]. However, the quality of the compacts was not analysed in this work.…”

Section: Methodsmentioning

confidence: 99%

Comparison of Cohesive Models in EDEM and LIGGGHTS for Simulating Powder Compaction

et al. 2018

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The purpose of this work was to analyse the compaction of a cohesive material using different Discrete Element Method (DEM) simulators to determine the equivalent contact models and to identify how some simulation parameters affect the compaction results (maximum force and compact appearance) and computational costs. For this purpose, three cohesion contact models were tested: linear cohesion in EDEM, and simplified Johnson-Kendall-Roberts (SJKR) and modified SJKR (SJKR2) in LIGGGHTS. The influence of the particle size distribution (PSD) on the results was also investigated. Further assessments were performed on the effect of (1) selecting different timesteps, (2) using distinct conversion tolerances to export the three-dimensional models to standard triangle language (STL) files, and (3) moving the punch with different speeds. Consequently, we determined that a timestep equal to a 10% Rayleigh timestep, a conversion tolerance of 0.01 mm, and a punch speed of 0.1 m/s is adequate for simulating the compaction process using the materials and the contact models in this work. The results showed that the maximum force was influenced by the PSD due to the rearrangement of the particles. The PSD was also related to the computational cost because of the number of simulated particles and their sizes. Finally, an equivalence was found between the linear cohesion and SJKR2 contact models.

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“…Nunes de Barros, F.; Bhaskar, A.; Singh, R. A Validated Model for Design and Evaluation of Control Architectures for a Continuous Tablet Compaction Process [5].…”

mentioning

confidence: 99%

Special Issue: Combined Scheduling and Control

Hedengren

Beal

2018

Processes

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This Special Issue (SI) of Processes, "Combined Scheduling and Control," includes approaches to formulating combined objective functions, multi-scale approaches to integration, mixed discrete and continuous formulations, estimation of uncertain control and scheduling states, mixed integer and nonlinear programming advances, benchmark development, comparison of centralized and decentralized methods, and software that facilitates the creation of new applications and long-term sustainment of benefits. Contributions acknowledge strengths, weaknesses, and potential further advancements, along with a demonstration of improvement over current industrial best-practice. Advanced optimization algorithms and increased computational resources are opening new possibilities to integrate control and scheduling. Some of the most popular advanced control methods today were conceptualized decades ago. Over a time span of 30 years, computers have increased in speed by about 17,000 times and algorithms such as integer programming have a speedup of approximately 150,000 times on some benchmark problems. With the combined hardware and software improvements, benchmark problems can now be solved 2.5 billion times faster; i.e., applications that formerly required 120 years to solve are now completed in 5 s [1]. New computing architectures and algorithms advance the frontier of solving larger scale and more complex integrated problems. Recent work demonstrates economic and operational incentives for merging scheduling and control. The accepted publications cover a range of topics and methods for combining control and scheduling. There were many submissions to the special issue, and about 50% were accepted for publication. The seven that were accepted have novel approaches, summary surveys, and illustrative examples that validate the methods and motivate further investigation. The articles are summarized below. Lefebvre, D. Dynamical Scheduling and Robust Control in Uncertain Environments with Petri Nets for DESs [2]. This paper is about the incremental computation of control sequences for discrete event systems in uncertain environments through implementation of timed Petri nets. The robustness of the resulting trajectory is also evaluated according to risk probability. A sufficient condition is provided to compute robust trajectories. The proposed results are applicable to a large class of discrete event systems, in particular in the domains of flexible manufacturing. Joglekar, G. Using Simulation for Scheduling and Rescheduling of Batch Processes [3]. This paper uses a BATCHES simulation model to accurately represent the complex recipes and operating rules typically encountered in batch process manufacturing. By using the advanced capabilities of the simulator (such as modeling assignment decisions, coordination logic, and plant operation rules), very reliable and verifiable schedules can be generated for the underlying process. Scheduling methodologies for a one-segment recipe and a rescheduling methodology for day-today decisions are ...

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A Validated Model for Design and Evaluation of Control Architectures for a Continuous Tablet Compaction Process

Cited by 8 publications

References 32 publications

RTD-based material tracking in a fully-continuous dry granulation tableting line

RTD-based material tracking in a fully-continuous dry granulation tableting line

Comparison of Cohesive Models in EDEM and LIGGGHTS for Simulating Powder Compaction

Special Issue: Combined Scheduling and Control

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