Adoption of Computational Fluid Dynamics (CFD) simulation is emerging as a game changer for continuous manufacturing applied to Active Pharmaceutical Ingredients (APIs). Use of CFD will foster simulation driven processes and designs that in return will shorten product-process development cycles, reduce energy requirements, lead to superior products and result in a shorter time-to-market.
Mixing: The Eulerian multiphase model provides an effective means for modeling two-phase and multiphase flows including those encountered during mixing. The extensive range of sub-models provided by STAR-CCM+ include drag, virtual mass, lift and turbulent drag forces, break-up and coalescence models for bubbles, and a granular flow model. The Eulerian multiphase model is ideal for studying the interacting streams and phases dispersed randomly in static mixers, stirred tanks, homogenizers and emulsifiers.
Solids Handling Solutions: STAR-CCM+ includes a Discrete Element Modeling (DEM) capability that is fully coupled with a numerical flow simulation in a single software environment. DEM simulates the motion of a large number of interacting discrete particles (such as tablets and capsules) and tracks the interaction between every particle in a numerically efficient manner, modeling contact forces and energy transfer due to collision and heat transfer between particles. STAR-CCM+ leads to solids handling solutions, whether you need to analyze the chaotic movement of particles in fluidized beds, improve tablet coating uniformity, or find a cost-effective solution for equipment corrosion.
Manufacturing Success: Optimate, a module in STAR-CCM+, enables intelligent design exploration and allows users to easily consider “what if” scenarios to maximize operating performance during the manufacturing process. With Optimate, you can also cost-effectively perform parametric studies and improve on the designs of impeller geometries, mixing tanks and other equipment. In addition, with the Lagrangian and Eulerian multiphase models in STAR-CCM+, you can assess the separation efficiency of particles in cyclones and accurately predict the pressure drop across the unit, as well improve the operation and construction of spray dryers and other equipment.
Shorten Time-to-Market: STAR-CCM+ is an ideal analysis environment for a wide range of pharmaceutical applications such as mixing, solids handling, separation, manufacturing, microfluidics and drug delivery. The complex flow-fields associated with these applications can be addressed with ease by using the high-end physics models delivered by STAR-CCM+, including the powerful DEM and multi-phase flow technologies. Using STAR-CCM+ will open the door to explore innovative ways to reduce cost and shorten time-to-market which is vitally important to the success of continuous manufacturing applied to APIs.