Utilizing in-situ Analytical Measurements for Batch Process Analysis and Control

Process analytical technology (PAT) is an established field within the chemical and pharmaceutical industries to directly measure high value and high throughput manufacturing processes. The goal of any in-situ analytical measurement system is to generate compositional information for both process control and process understanding with timely, actionable information. Any installation is justified by contributing toward advancing manufacturing concepts such as quality by design, real-time release, just in time manufacturing, lean manufacturing and even right to operate.

Successful implementation of PAT methodologies starts at small scale with feasibility studies and process development, carried forward into the pilot plant and implemented at manufacturing scale. Knowledge is gained through each step to ensure the consistency of the reaction characteristics and to identify factors imparted upon scaleup. The goal is gaining understanding of the compositional changes and sample makeup within the chemical process as each successive reaction builds in value.

Building upon advances in data science and informatics, PAT measurements can introduce a direct feedback for control systems. Coupling the inputs and sensory outputs of the plant data systems with the real-time analysis can lead to identifying new schemes for monitoring key manufacturing steps or determining attributes to avert costly upsets. Bringing all of the elements together can help realize the goal of being preemptive versus reactive.