Extended validation and verification of XPS/AVL-Fire™, a computational CFD-DEM software platform

Forgber, Thomas; Toson, Peter; Madlmeir, Stefan; Kureck, Hermann; Khinast, Johannes G.; Jajčević, Dalibor

doi:10.1016/j.powtec.2019.11.008

Cited by 28 publications

(10 citation statements)

References 48 publications

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“…Over the past years, we have created a database of the most common twin-screw extruder elements of major pharma extruder manufacturers of various scales (12-mm, 16-mm, 18-mm, and 27-mm extruder sizes) (30,(83)(84)(85). Since analyzing the flow and mixing behavior in such detail is computationally expensive, we developed an in-house software for accelerated simulations running on graphic cards (GPUs): the eXtended Particle Systems (XPS) software (97)(98)(99)(100)(101)(102)(103)(104)(105)(106)(107)(108)(109). It is a powerful simulation platform for simulating not only complex fluids via SPH, but also complex powders via the discrete element method (DEM) with additional coupling to conventional CFD software.…”

Section: Process Development and Control Process Setup And Scale-up Vmentioning

confidence: 99%

Developing HME-Based Drug Products Using Emerging Science: a Fast-Track Roadmap from Concept to Clinical Batch

et al. 2020

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This paper presents a rational workflow for developing enabling formulations, such as amorphous solid dispersions, via hot-melt extrusion in less than a year. First, our approach to an integrated product and process development framework is described, including state-ofthe-art theoretical concepts, modeling, and experimental characterization described in the literature and developed by us. Next, lab-scale extruder setups are designed (processing conditions and screw design) based on a rational, model-based framework that takes into account the thermal load required, the mixing capabilities, and the thermo-mechanical degradation. The predicted optimal process setup can be validated quickly in the pilot plant. Lastly, a transfer of the process to any GMP-certified manufacturing site can be performed in silico for any extruder based on our validated computational framework. In summary, the proposed workflow massively reduces the risk in product and process development and shortens the drug-to-market time for enabling formulations.

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Section: Process Development and Control Process Setup And Scale-up Vmentioning

confidence: 99%

Developing HME-Based Drug Products Using Emerging Science: a Fast-Track Roadmap from Concept to Clinical Batch

et al. 2020

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“…The scalar transport of an arbitrary gaseous species “i” is described by the following equation: μ i,vap is the mass fraction of the gas species, D eff is the diffusion coefficient, and S i,vap is the gas species source term. Forgber et al ( 39 ) have provided an in-depth overview of the models used and validated the momentum, heat, and mass transfer models for spheres.…”

Section: Simulation Modelmentioning

confidence: 99%

“…The coated surface area is calculated using the above-mentioned algorithm of Kariuki et al ( 48 ), which is also applied to calculate the evaporation rate. For more information about this approach, please refer to Forgber et al ( 39 ) .…”

Section: Simulation Modelmentioning

confidence: 99%

Validating a Numerical Simulation of the ConsiGma(R) Coater

Boehling

Jacevic

Detobel³

et al. 2020

AAPS PharmSciTech

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Continuous manufacturing is increasingly used in the pharmaceutical industry, as it promises to deliver better product quality while simultaneously increasing production flexibility. GEA developed a semi-continuous tablet coater which can be integrated into a continuous tableting line, accelerating the switch from traditional batch production to the continuous mode of operation. The latter offers certain advantages over batch production, e.g., operational flexibility, increased process/product quality, and decreased cost. However, process understanding is the key element for process control. In this regard, computational tools can improve the fundamental understanding and process performance, especially those related to new processes, such as continuous tablet coating where process mechanics remain unclear. The discrete element method (DEM) and computational fluid dynamics (CFD) are two methods that allow transition from empirical process design to a mechanistic understanding of the individual process units. The developed coupling model allows to track the heat, mass, and momentum exchange between the tablet and fluid phase. The goal of this work was to develop and validate a high-fidelity CFD-DEM simulation model of the tablet coating process in the GEA ConsiGma® coater. After the model development, simulation results for the tablet movement, coating quality, and heat and mass transfer during the coating process were validated and compared to the experimental outcomes. The experimental and simulation results agreed well on all accounts measured, indicating that the model can be used in further studies to investigate the operating space of the continuous tablet coating process.

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“…u i,vap is the mass fraction of the gas species, D eff is the diffusion coefficient andS i,vap is the gas species source term. Forgber et al [39] have provided an in-depth overview of the models used and validated the momentum, heat, and mass transfer models for spheres.…”

Section: Cfd-dem Modelmentioning

confidence: 99%

“…The coated surface area is calculated using the above-mentioned algorithm of Kariuki et al [49], which is also applied to calculate the evaporation rate. For more information about this approach, please refer to Forgber et al [39].…”

Section: Spray Coating Modelmentioning

confidence: 99%

Validating a numerical simulation of the ConsiGma® semi-continuous tablet coating process

Böhling¹,

Jajčević²,

Detobel³

et al.

Authorea

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GEA developed a semi-continuous tablet coater which can be integrated into a continuous tableting line, accelerating the switch from traditional batch production to the continuous mode of operation. Process understanding is the key element for process control and is important for continuous manufacturing. Computational tools can improve the fundamental understanding and process performance, especially those related to new processes, such as continuous tablet coating where process mechanics remain unclear. In the last years, Computational Fluid Dynamics and the Discrete Element Method have increasingly been applied in the pharmaceutical industry. The goal of this work was to develop and validate a high-fidelity CFD-DEM simulation model of the tablet coating process in the GEA ConsiGma® coater. Simulation results for the tablet movement, coating quality, and heat and mass transfer during the coating process were validated and compared to the experimental outcomes. The experimental and simulation results agreed well on all accounts measured.

show abstract

Extended validation and verification of XPS/AVL-Fire™, a computational CFD-DEM software platform

Cited by 28 publications

References 48 publications

Developing HME-Based Drug Products Using Emerging Science: a Fast-Track Roadmap from Concept to Clinical Batch

Developing HME-Based Drug Products Using Emerging Science: a Fast-Track Roadmap from Concept to Clinical Batch

Validating a Numerical Simulation of the ConsiGma(R) Coater

Validating a numerical simulation of the ConsiGma® semi-continuous tablet coating process

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