Film Scrap Reduction via Parameter Correlation
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Solution Overview
Problem
Current film dosage manufacturing processes result in significant scrap material, particularly when producing self-supporting films, leading to inefficiencies and increased costs due to the waste of expensive active pharmaceutical ingredients.
Innovation Solution
A method and system that utilize a computer-based system to determine and adjust processing parameters, such as mixer settings and coating widths, to minimize scrap production during the manufacturing of self-supporting films, optimizing yield and reducing waste by correlating scrap factors with processing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If current manufacturing processes are used to produce self-supporting film dosages, then individual doses can be formed, but significant scrap material is generated leading to material waste and increased costs
Solution Approach 1:
The system implements a feedback mechanism where scrap factors are determined from processing data, correlated with processing parameters, and used to adjust those parameters in real-time or between runs. This closed-loop control continuously optimizes the manufacturing process to minimize scrap generation while maintaining productivity.
Solution Approach 2:
The invention systematically varies processing parameters (such as coating width, mixer settings, drying conditions) to identify optimal settings that minimize scrap. By correlating scrap factors with specific parameters and adjusting them, the process transforms from a fixed procedure to an optimized, adaptive manufacturing system.
2Loss of substance
If processing parameters are adjusted to reduce scrap, then material yield improves, but process complexity increases due to data compilation and parameter correlation requirements
Solution Approach 1:
The processor performs multiple functions: compiling production data, determining scrap factors, correlating with processing parameters, and adjusting parameters. This multi-functional system consolidates what could be separate complex subsystems into a single integrated unit, reducing overall system complexity while achieving scrap minimization.
Solution Approach 2:
The system uses its own processing data to automatically determine scrap factors and adjust parameters without external intervention. The manufacturing system serves itself by using embedded sensors and processors to monitor and optimize its own operation, reducing the need for external complex control systems.
Data Source
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AI summary
The present invention relates to a method of optimizing self-supporting film production which includes the steps of: determining at least one scrap factor which relates to a total amount of scrap in processing a film product; correlating the at least one scrap factor to at least one processing parameter; and adjusting the at least one processing parameter to reduce the total amount of scrap in processing the film product.