Modeling, experimental trials, and design space determination for the GEA ConsiGma™ coater

Kemp, Ian; Iler, Lewis; Waldron, M. Petkovski P.; Turnbull, Neil

doi:10.1080/07373937.2018.1463244

Cited by 12 publications

(9 citation statements)

References 17 publications

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“…These tablets move back into the bulk bed within a few seconds and their surface must be sufficiently dry to avoid them sticking together, causing surface damage or "twinning". Current models were reviewed by Kemp et al [6], and can include four main aspects:…”

Section: Tablet Film Coatingmentioning

confidence: 99%

“…The first two categories are routinely used in operation [7] -van den Ban et al However, little had previously been done to study tablet surface kinetics, although Ebey [8] noted that heat and mass balances could not explain all observations and proposed an Environmental Equivalency (EE) factor to allow for this. Kemp et al [6] demonstrate that the locus of the boundary where overwetting and other adverse effects occur is dependent mainly on exhaust temperature and secondarily on spray rate. Again, this leads logically to the conclusion that if the size of the design space is to be maximized, it will have a sloping lower boundary.…”

Section: Tablet Film Coatingmentioning

confidence: 99%

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Simultaneous wetting and drying: Fluid bed granulation and tablet film coating

et al. 2019

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Simultaneous wetting and drying occur in processes such as fluid bed (top spray) granulation, Wurster coating and tablet film coating. This gives control challenges, as the spraying and evaporation processes must be carefully balanced and the operating window is significantly narrower than for standalone drying processes. Significant recent advances in modelling have led to effective scale-up and operational strategies. Factors such as flow cessation during filter bag shaking can have a major effect. A design space can be predicted which is often non-orthogonal, and pharmaceutical regulatory authorities have accepted filing submissions using a design space justified by mechanistic modelling.

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Section: Tablet Film Coatingmentioning

confidence: 99%

Section: Tablet Film Coatingmentioning

confidence: 99%

Simultaneous wetting and drying: Fluid bed granulation and tablet film coating

et al. 2019

Self Cite

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“…A full simulation of the ConsiGma® tablet coating process requires the above-mentioned four-way coupling approach. Although existing models do consider the heat and mass transfer from a macroscopic (integral) point of view, they do not resolve the local tablet state (e.g., wetness or coating quality) (6,22). The approach presented in this work involves the development of an algorithm for the coupling of momentum, heat and mass transfer in the ConsiGma® filmcoating equipment for realistically shaped tablets.…”

Section: Introductionmentioning

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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“…Since the inline measurements are typically intrinsic to the process design, CM allows enhanced process control [4]. Above all, CM requires a high level of process understanding [5], [6] In light of the transition from batch to continuous manufacturing, GEA developed the ConsiGma® continuous processing line to process powder raw materials into tablets [7]. There are two types of ConsiGma® lines: the ConsiGma® continuous tableting line (CTL) and the continuous direct compression line (CDC).…”

Section: Introductionmentioning

confidence: 99%

“…A full simulation of the ConsiGma® tablet coating process requires the above-mentioned four-way coupling approach. Although existing models do consider the heat and mass transfer from a macroscopic (integral) point of view, they do not resolve the local tablet state (e.g., wetness or coating quality) [6] [22]. The approach presented in this work involves the development of an algorithm for the coupling of momentum, heat and mass transfer in the ConsiGma® film-coating equipment for realistically-shaped tablets.…”

Section: Introductionmentioning

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.

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Modeling, experimental trials, and design space determination for the GEA ConsiGma™ coater

Cited by 12 publications

References 17 publications

Simultaneous wetting and drying: Fluid bed granulation and tablet film coating

Simultaneous wetting and drying: Fluid bed granulation and tablet film coating

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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