(665f) Modeling and Control of a Continuous Tablet Manufacturing Process Using Simulink

Continuous manufacturing is garnering significant attention in the pharmaceutical industry due to its potential to enhance efficiency, increase output, and reduce operating costs and waste. Achieving a stable and continuous process necessitates the implementation of robust process control strategies. While PID control remains prevalent in the chemical engineering industry, the complexity of pharmaceutical processes calls for advanced, data-driven control approaches.

This presentation showcases a Simulink model of a continuous tablet manufacturing process, detailing the integration of advanced control strategies. The model comprises several subsystems, including the feeder, blender, roller compaction hopper, roller compaction, conical screen mill, tablet press hopper, and tablet press. Our objective is to maintain critical parameters such as API concentration, blender flow rate, tablet mass, and hardness at desired setpoints.

We will demonstrate the transition from traditional PID control to a unified Model Predictive Control (MPC) strategy, highlighting the benefits of MPC in managing complex interactions within the process. Additionally, the direct conversion of MPC to structured text code for seamless PLC integration will be discussed. As for future steps, we will discuss leveraging high-fidelity simulation data and AI-based reduced order models. We illustrate the potential of these advanced control strategies to optimize process parameters and enhance product quality.

This case study not only underscores the advantages of advanced process control in continuous manufacturing but also contributes to the broader discourse on innovative control strategies in pharmaceutical applications.