Enabling energy‐efficient manufacturing of pharmaceutical solid oral dosage forms via integrated techno‐economic analysis and advanced process modeling

Sampat, Chaitanya; Kotamarthy, Lalith; Bhalode, Pooja; Chen, Yingjie; Dan, Ashley; Parvani, Sania; Dholakia, Zeal; Singh, Ravendra; Glasser, Benjamin J.; Ierapetritou, Marianthi; Ramachandran, Rohit

doi:10.1002/amp2.10136

Title: Enabling energy‐efficient manufacturing of pharmaceutical solid oral dosage forms via integrated techno‐economic analysis and advanced process modeling

Journal Article · 15 July 2022 · Journal of Advanced Manufacturing and Processing

DOI: https://doi.org/10.1002/amp2.10136 · OSTI ID:1876518

Sampat, Chaitanya ^[1]; Kotamarthy, Lalith ^[1]; Bhalode, Pooja ^[1]; Chen, Yingjie ^[2]; Dan, Ashley ^[1]; Parvani, Sania ^[1]; Dholakia, Zeal ^[1]; Singh, Ravendra ^[1]; Glasser, Benjamin J. ^[1]; Ierapetritou, Marianthi ^[2];

^[1]

Department of Chemical and Biochemical Engineering Rutgers‐The State University of New Jersey Piscataway New Jersey USA
Department of Chemical and Biomolecular Engineering University of Delaware Newark Delaware USA

Abstract The global pharmaceutical industry is a trillion‐dollar market. However, the pharmaceutical sector often lags in manufacturing innovation and automation which limits its potential to maximize energy efficiency. The integration of techno‐economic analysis (TEA) with advanced process models as part of an overarching smart manufacturing platform, can help industries create business models, which can be adapted for manufacturing to reduce energy consumption and operating costs while ensuring product quality which can further enable a more sustainable process operation. In this study, a rational design of experiment on three unit‐operations (wet granulation, drying, and milling) was performed on a batch (case 1) and continuous (case 2) pharmaceutical process to obtain experimental data. Process models for predicting product quality and energy efficiency of each of the three‐unit operations were developed. The experimental data were used to validate the models and good agreement was observed. The energy consumption of each unit operation was calculated using statistical models relating the power consumption and the process parameters. The developed process models and energy models were further integrated into a TEA framework, which quantified the energy and monetary cost of manufacturing for both batch and continuous manufacturing cases. With this integrated framework, energy costs savings of ~33% was obtained in the continuous manufacturing process (case 2) over the batch process (case 1).

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Sponsoring Organization:: USDOE

OSTI ID:: 1876518

Journal Information:: Journal of Advanced Manufacturing and Processing, Journal Name: Journal of Advanced Manufacturing and Processing Journal Issue: 4 Vol. 4; ISSN 2637-403X

Publisher:: Wiley Blackwell (John Wiley & Sons)Copyright Statement

Country of Publication:: United States

Language:: English

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