Innovate UK project to introduce computer modelling to improve pharmaceutical processes

A £700,000 project is aiming to help pharmaceutical manufacturers improve the way they manufacture particulates, by using computer simulations.

The Manufacturing of Particulate Process (Models MPP) project is an Innovate UK initiative being led by the Centre for Process Innovation (CPI). The two-year project looks to improve industrial productivity by introducing computer models across manufacturing processes.

The funding is being used to connect industry and academia and has so far resulted in the development of a generic framework that manufacturers can use to translate particle models into industrial practice.

The framework uses a decision support tool that allows easier access and adoption by UK-based industrial organisations. The models are designed to accelerate development of products whilst also improving productivity and reducing the cost of manufacturing processes. Specifically, it’s designed to enable scientists and engineers to develop models that simulate different parts of manufacturing processes to do with particulates. More so, it’s hoped that this will improve the properties of very fine cohesive powders used by pharmaceutical manufacturers and other industries.

Dr Caroline Kelly, CPI Technology and innovation officer and manager of the Models MPP project, said: “It has been a privilege to work with the world-leading partners to deliver a step-change in how particle modelling can be translated from academia into real industrial formulations.

“It is also exciting to see the potential opportunities for how this new capability will be deployed, particularly in the new granulation capability recently established within our formulation facility.

“This modelling project is the first in a series of five capability-build projects to complete and we look forward to similar success stories over the next 18 months.”

The project used software platforms from software processes and simulations providers EDEM and Process Systems Enterprise (PSE) to develop the models, which were than validated using real-life trials.

Dr Sean Bermingham, head of formulated products at PSE, said: “This CPI co-ordinated project has been an excellent demonstration of how the gPROMS Formulated Products Population Balance Modelling (PBM) environment developed through the ADDoPT pharmaceutical digital design project can be readily applied to other formulated products industries, including fast moving consumer goods and specialty chemicals.

“Additionally, the project provided a unique opportunity to move DEM-PBM coupling from the academic research stage to an industrially applied and commercially supported capability.

“The extensive progress made in the last two years has demonstrated the strength of this well-balanced consortium involving leading academics, early industry adopters, and technology providers.”