(343d) A Universal Control Concept for Complex Manufacturing Lines

With the implementation of advanced manufacturing concepts such as continuous operation, integration of different process routes or modular manufacturing, the control of the process and the related product quality becomes more complex. In modern high-speed manufacturing, no delays from measurements can be afforded between unit operations as with traditional in-process controls or end-product testing. Real-time information on the material state and associated control actions are required.

This talk will present a universally applicable control concept, which allows the highest level of flexibility for processing, equipment and automation level. The concept can deal with a combination of batch-wise and continuously operated process steps, with manual and automated operation, with different scales of equipment and with digital and manual data acquisition. It is demonstrated at a compact end-to-end manufacturing line for tablets. The control strategy is not only based on data from classical PAT sensors, but also from equipment and from soft sensors. As an example, the content is monitored and controlled using soft sensors and the feeder data. A digital twin of the entire process chain is fed with process and quality information and executes the control actions. The complete process control is realized in an automation platform with human machine interface (HMI). Additionally, some novel process routes have been realized: A suspension of active pharmaceutical ingredient (API) is directly fed into hot melt extrusion (HME), which is combined with direct compaction (DC).