Continuous Powder Processing Configuration Using Emulator Feedback
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Solution Overview
Problem
Existing continuous processing systems for developing drug candidates face challenges in configuring optimal formulations efficiently due to variability in material and process parameters, leading to high consumption of expensive materials and prolonged development times.
Innovation Solution
An emulator with reduced processing capacity is used to emulate system components, coupled with a database correlating parameter data from powder, component, process, and product properties, allowing for targeted configuration through predictive modeling and real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional continuous processing systems are used for formulation development, then comprehensive processing capability is achieved, but material consumption increases and development time prolongs
Solution Approach 1:
The patent applies the copying principle by creating a digital twin (virtual model) of the continuous processing system that replicates its behavior and characteristics. This virtual copy allows formulation development and optimization to be performed computationally, eliminating the need for extensive physical experiments with expensive materials while maintaining processing capability fidelity.
Solution Approach 2:
The patent implements preliminary action by using the digital twin to perform virtual formulation development, optimization, and validation before actual production trials. This preliminary computational work identifies optimal formulations and process parameters in advance, reducing material consumption during subsequent physical experiments and production scaling.
2Reliability
If conventional continuous processing systems are used for formulation development, then comprehensive processing capability is achieved, but development time increases
Solution Approach 1:
The digital twin creates a virtual replica of the processing system that enables parallel computational experimentation without time constraints of physical systems. Multiple formulations and process conditions can be evaluated simultaneously in silico, dramatically accelerating formulation development while maintaining processing capability accuracy.
Solution Approach 2:
The system performs preliminary virtual optimization and validation of formulations and process parameters before physical implementation. This advance computational work reduces the number of iterative physical trials needed, thereby shortening overall development time while ensuring processing capability is properly validated.
3Ease of operation
If manual data gathering and evaluation is used, then simplicity of operation is maintained, but measurement precision and completeness of parameter data decrease
Solution Approach 1:
The patent implements automated feedback loops where sensors continuously monitor process parameters and feed data back to the digital twin and control system. This automated feedback mechanism ensures comprehensive and precise data collection without increasing operational complexity, as the system self-regulates and continuously optimizes based on real-time measurements.
Solution Approach 2:
The patent replaces manual data gathering and evaluation with automated computational systems, sensors, and algorithms. This substitution of mechanical/manual operations with automated electronic and computational systems maintains ease of operation while dramatically improving measurement precision, data completeness, and analysis capability.
Data Source
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AI summary
The invention pertains to a method and device for configuring a continuous processing system for processing powder materials, wherein the continuous processing system comprises several system components, namely powder feeders for feeding powder materials through inlets of the continuous processing system, and a mixing device for mixing the powder materials fed by the powder feeders to obtain a powder mixture. The invention also pertains to a continuous processing system.