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This study developed a computational model for continuous tablet coating, validating it with experimental data. The model accurately simulates tablet movement and coating quality, aiding process optimization in pharmaceutical manufacturing.

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Area of Science:

  • Pharmaceutical Engineering
  • Computational Fluid Dynamics
  • Discrete Element Method

Background:

  • Continuous manufacturing offers advantages over batch production in pharmaceuticals, including improved quality and flexibility.
  • Understanding the mechanics of continuous tablet coating is crucial for process control and optimization.
  • Computational tools like CFD-DEM can bridge the gap between empirical design and mechanistic understanding.

Purpose of the Study:

  • To develop and validate a high-fidelity computational model for continuous tablet coating.
  • To simulate heat, mass, and momentum exchange between tablets and the fluid phase.
  • To compare simulation results with experimental data for process validation.

Main Methods:

  • Utilized a coupled Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) model.
  • Simulated the tablet coating process within the GEA ConsiGma® coater.
  • Validated simulation outputs against experimental measurements of tablet movement, coating quality, and heat/mass transfer.

Main Results:

  • The CFD-DEM model successfully simulated tablet movement, coating quality, and heat/mass transfer.
  • Simulation results showed strong agreement with experimental outcomes.
  • The validated model provides a tool for further investigation of the continuous tablet coating operating space.

Conclusions:

  • The developed CFD-DEM model is a reliable tool for understanding and optimizing continuous tablet coating processes.
  • This approach facilitates a transition from empirical to mechanistic process design.
  • The model's validation supports its use in future research for continuous pharmaceutical manufacturing.