Advanced modelling and simulation for the Pharmaceuticals and Lifestyle sectors

Advanced Process Modelling in the pharmaceuticals sector

See our articles on modelling in the pharmaceutical industry:

Quality through quantification – NextGen Quarterly Pharmaceutical review
Quality through quantification: how understanding generates profit – NextGen Quarterly review TalkBack slot

Process modelling has not traditionally played a significant role in design and operation of pharmaceutical processes.

This is partly because in the past the major focus has been on molecule development rather than manufacture, and also simply because simulation tools have not catered for the specialised requirements of the pharmaceutical industry.

However, commercial pressures for greater efficiency, better understanding of processes, more reliable scale-up and the move from batch to continuous processing are changing this.

At the same time, modelling software such as gPROMS is now capable of dealing with the complex processes encountered in pharmaceuticals.

PSE customers include the world's largest pharmaceutical companies, who are applying modelling in the areas described below.

Similar considerations apply to the lifestyle and consumer products sectors, with innovative companies such as Procter & Gamble adopting Advanced Process Modelling and Model-Based Innovation techniques to accelerate product development and improve manufacturing processes in many different areas.

Application areas

PSE now provides a comprehensive range of tools, models and services for the pharmaceutical industry. Click on the graphic or see below for more information.

"ModelCare helps deliver all kinds of projects rapidly while transferring modelling know-how to customer personnel".

Batch vs. continuous

Modelling plays an essential role in the move from batch to continuous processing.

All of the technologies and activities described above help provide reliable quantitative information that minimises the risk in moving from batch to continuous production.

High-accuracy predictive models can be used to design the optimal continuous process equipment within the context of the entire continuous process, and to test every possible operating eventuality.

Batch process optimisation

gPROMS was specifically designed as a modelling tool for optimisation of batch processes.

gPROMS' award-winning dynamic modelling and optimisation capabilities, coupled with its powerful task language, are ideally suited to — for example — maximising product yield or minimising batch time subject to process and material constraints.

Process Analytical Technology (PAT) and modelling

Advanced Process Modelling is a key technology for providing the high-quality information required by process analytical technology.

Models can be taken online as part of the automation system for continuous process monitoring and to provide inferred ("soft sensed") measurements.

Tools

gPROMS Advanced Process Modelling (APM) environment, a sophisticated tool for multi-scale modelling of complex processes and phenomena of all kinds
A comprehensive set of tools for model validation, including parameter estimation and model-based data analysis and experiment design capabilities, that allows the maximum amount of information to be extracted from laboratory and pilot plant experimental data
Comprehensive tools for batch process optimisation, in addition to the tools for optimisation of continuous processes.

Models

The Advanced Model Library for Solution Crystallisation (AML:SC), technology-leading models that represent many years' accumulated modelling expertise
The Advanced Model Library for Gas-Liquid Contacting (AML:GLC), technology-leading models that can be used to model any kind of separation process
The Hybrid gPROMS–CFD Multizonal interface for linking CFD and APM models.
Advanced reaction models of all kinds
State-of-the-art membrane separation models.

Services:

ModelCare model configuration, validation and execution services, for rapid project execution of all pharmaceutical modelling projects, and transfer of know-how to customer personnel
Expert Consulting services, to analyse and formulate modelling requirements, execute model-based analyses, interpret results and advise on action – for example, appropriate experiments and measurement techniques
Model-Based Innovation services, to help integrate R&D effort with engineering design and operational improvement.

We also provide well-proven and cost-effective project methodologies for modelling all types of pharma process.