(26g) In silico Design Space Investigation of a Novel Tablet Coating Process Using Advanced Coupled Simulations

Continuous manufacturing is increasingly used in the pharmaceutical industry, as it promises to deliver better product quality while simultaneously increasing production flexibility. GEA developed the ConsiGma line(s) to be integrated into granular downstream processes. The specially developed tablet coater is unique in its design and process mechanics. It uses high rotation rates compared to traditional drum batch coaters.

Computational methods are increasingly used in the pharmaceutical industry as well and facilitate a deeper understanding of the process mechanics. 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. This work used CFD-DEM simulations to increase the understanding of the ConsiGma® tablet coater through a multi-variant design study. The results are split into two categories: first, the tablet bed behavior (mechanics) will be investigated and second, the thermodynamically behavior will be studied.

The goal of this work is to present a comprehensive overview of the influence the varying process and material input parameters have on the process output responses. The simulations show how the drum load, rotation rate, and material properties all influence the tablet bed behavior. The same can be said that the drying air flow rate, spray rate, and inlet temperature can influence the coating quality which is tracked through the tablet temperature and wetness. Overall it could be shown that simulations allow for the full coating process to be recreated numerically which, in return, saves material and equipment time typically required for process development.