One of the critical functions within pharma industries is intralogistics. Intralogistics is the process of automating, optimizing and managing the physical flows of materials inside warehouse and to/from warehouse across Active Pharmaceutical Ingredients (API) production, Aseptic Production (AP), assembly and packaging facilities within pharma industries. Simulating the materials flow help the...
With diabetes being one of the world’s fastest growing health emergencies, demand for diabetes medication is rising. This calls for expanding production capacity through construction of new facilities as well as increasing capacity within existing facilities. In this work, a systematic method for capacity ramp-up based on data-driven modelling and simulation of an API purification process is...
In the field of API production, process control and stability are crucial for ensuring a maximum capacity and most importantly that final API meets the required quality, as any deviation from these targets can have a dire consequence on the patient’s life. One promising approach to address these challenges in the production is the use of a digital twin, which is a virtual replica of the...
Topics in digitalisation and industry 4.0 have become the centre point of a new frontier in the chemical and biochemical manufacturing industry over the last decade. Especially the area of Digital Twins (DT) is diligently being explored by industry and academia to improve large-scale operational efficiency and -characterisation through tighter data integration between the physical system and...
In the current era of Industry 4.0 and cyber-physical systems, the way production systems are designed and managed has been significantly transformed by digital technologies. In this context, the Digital Twin (DT) has emerged as a promising simulation paradigm to support decision-making through various engineering applications. In fact, DT can be considered a virtual replica of a physical...
In recent years, there has been a significant increase in the deployment of cyber-physical production systems (CPPS) across various industries. CPPS consist of interconnected devices and systems that combine physical and digital elements to enhance the efficiency, productivity, and reliability of manufacturing processes [1]. However, with the proliferation of these complex systems, there is a...
Conceptual Digital Twin Framework for Quality Assurance in the Injection Molding Industry: Technical and Digital Skill Perspectives
Till Böttjer, Sara Blasco Román
In order to maintain a competitive edge in the market, companies strive to improve the quality and performance of their products while also minimizing downtime and maintenance costs. One of the ways to achieve this is...
Introduction:
Pork is one of the most important meat products for the European Union, with the EU being the world's largest pork exporter. In 2020, the EU exported over 4 million tons of pork, with a total value of €7.7 billion (Eurostat, 2021). The largest pork-exporting countries within the EU include Spain, Denmark, and Germany.
However, despite the significant export value of...
The transition from batch to continuous manufacturing in the pharmaceutical industry is well underway, leading to the investigation of new technologies. Digital Twin (DT) is one of the topics promising to optimize processes and increase product quality by integrating the sensor data and simulation models.
In this presentation, we report on the main steps for implementing the DT for a...
The pace of digitalization is rapidly accelerating with businesses and industries utilizing technologies such as IoT, cloud computing, big data analytics, and AI to create digital twins (DTs) - virtual replicas of physical systems or environments. DTs offer a powerful framework for integrating the physical and virtual worlds, enabling more efficient and effective decision-making. Industries...
Separation and purification processes are responsible for a large portion of the production cost in the bioprocessing industry (McGlaughlin, 2012). As such, significant interest and efforts have been geared toward improving existing processes or developing new and innovative ones. Extractive recovery of products from fermentation broth provides an attractive way of separating heat-sensitive or...
Digital Twins are essential in Bioprocessing 4.0 as virtual representations of bioprocess components. Existing coupling methods between Computational Fluid Dynamics (CFD) and biological models focus on simple metabolic approaches, resulting in complex simulations that strain high-performance computers.
We propose an automated compartmentalization approach for bioreactors using unsupervised...
The digital twin concept represents the most appealing opportunity to move forward condition-based and predictive maintenance practices. Enabling such a paradigm shift for civil engineering systems would allow for reducing lifecycle (economic and social) costs and increasing the system safety and availability. This is nowadays possible as the installation of permanent real-time data collecting...
Lactobacillus rhamnosus (L. rhamnosus) represent a valuable potential for applications in the continuously growing multi-billion euro functional-food industry. This commensal microorganism is known for its multiple health benefits including immunomodulatory and gut-stimulating properties. Optimizing the production of L. rhamnosus biomass can enhance the efficacy of its use. In this...
Advancements in technology and data access are followed by significant changes in the scope of engineering work. In Industry 4.0, sensor technologies enable improved monitoring, diagnostic, prognostic and prescriptive analytic capabilities. Systems and processes are now paired with digital twins, a digital asset that parallels the physical assets. This evolution triggers a shift from...
“Cost is more important than quality, but quality is the best way to reduce costs”. In the spirit of this inspirational quote from Genichi Taguchi, traditional Robust Design has developed into a well-established part of the quality-by design domain. Including widely known tools such as signal-to noise ratios, quality loss functions, crossed-array experiments, etc., Robust Design offers a...
“All models are wrong, but some are useful”. This fundamental quoting from George RP Box puts focus on the awareness on actual uncertainty and approximations that all models have to deal with. In engineering most product designs nowadays are developed and built including significant simulation efforts based on advanced multi-physics models. In aerospace engine design mechanical,...
Instrumentation, control and automation for industrial chemical and biochemical processes to attain cost-effective and safe process operation are highly dependent on reliability of the real-time measurements. Despite considerable development of online sensors during the past decades, their dependability is still impaired due to various fouling and failing issues. Occasionally unsatisfactory...
Currently, Artificial Intelligence (AI) and more specifically generative models, are substantially criticized due to concerns about the lack of ethical regulation concerning its use and the impact that it could have on society. However, if applied correctly and ethically, AI could provide the opportunity for educators to automate repetitive tasks with stimulant new experiences for the...
Column chromatography is a workhorse unit operation for purification of proteins and pharmaceuticals. Most column chromatography unit operations are run in batch-mode although continuous chromatography has the potential to increase productivity and reduce the solvent consumption. Operating continuous chromatography requires having multiple columns in series and/or parallel. The operation is...
In the chemical-, biochemical-, and food production industries vast amounts of process data are being recorded using inline/online sensor measurements and offline laboratory measurements. Putting this process data to work through implementation of operator assistance tools, control systems, and digital twins has gained renewed interest in industry [Udugama 2020]. Introduction of Big-Data...
Mammalian cells, particularly Chinese Hamster Ovary (CHO) cells, used for the production of recombinant proteins has gained widespread popularity in recent years due to their capability to produce proteins that are more similar to those found in humans [1], an essential feature in the development of therapeutics. CHO cells are recognized as one of the most reliable mammalian cell lines due to...
With the recent technological advances, there is a continuing trend to increase the level of detail of digital twins to correctly capture the behavior of a complex system (Tao et al., 2019). Increasing complexity introduces challenges for maintaining the physical-to-digital alignment (Tan and Matta, 2022).
Given the short-term decision support that must be provided by digital twins, it is...
In light of the advances of simulation technology over the last decades, engineering design increasingly turns towards simulation-driven practices. However, with the enormous possibilities for parametric optimization, it is often neglected that many other design decisions require efficient screening to gain insights about the significance of inputs. Examples include the choice of different...
Scaling the production needs from CMC to flexible scale or large-scale fermentation-based production of APIs (like insulin) is a cumbersome endeavor. Even though key operational process parameters have been validated at development scale and common scale up methods have been applied, the variation in space, time, and yield can differ considerably from site to site. This presentation attempts...
Digitalization and especially Digital twins have become a new frontier in the biomanufacturing- and processing industries. The development of these technologies promises to improve lean and intelligent production opportunities within these sectors by addressing model complexities with more data driven and hybrid modeling approaches. These methods employ a tight integration between the digital...
Polymer additive manufacturing (AM) technology is a relatively young and highly versatile manufacturing process which focuses on creating intricate geometries that would be difficult or impossible to achieve with other manufacturing methods. It is a type of AM that involves the layer-by-layer construction of three-dimensional objects using polymers as the raw material. Polymer AM has the...
Crystallization processes are important and widely used unit operations in the pharmaceutical industry and there is a need to understand and improve the performance of these processes in terms of e.g. yield and batch time as well as the performance of downstream processes affected by crystal size and shape e.g. yields and processing times of subsequent centrifugation, filtration and drying...