Vial filling is a critical step in pharmaceutical manufacturing, requiring precise control to ensure product quality, fill volume consistency, and compliance with regulatory standards. This study utilizes Computational Fluid Dynamics (CFD) simulations to analyze fluid flow dynamics during the filling process, accounting for variables such as nozzle geometry, fluid properties, and filling speed. The pharmaceutical product in question—a 5 mL suspension with non-Newtonian behavior—presented unique challenges, including shear sensitivity and the complexity of modeling various nozzle tip designs.
This case study showcases the comprehensive workflow involved in model development, encompassing parameter configuration, the simulation of surface tension and air-liquid interfaces, as well as dynamic fluid properties. Additionally, it highlights the application of data analytics for multidimensional optimization and parametric CFD, offering valuable insights into enhancing process efficiency and reliability.
