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Digital Process Twin - Pharma - Solvent switch
Digital process twin reduces production time and costs at J&J Innovative Medicine

Pharmaceuticals

J&J Innovative Medicine

Geel Belgium

Belgium
Geel,
Belgium
Sustainability
Currently, the solvent swap step is a time and cost-intensive process. These processes tend to be time-intensive, slow, require a lot of operator involvement and consume a lot of solvent.  Here the Digital Processs Twin can enable the operator to make the right decision concerning the trade-off between high energy cost and increasing pressure.  Additionally, the Digital Process Twin should also be used for scaling up production.
The POC is an Online Model Deployment optimization of a solvent swap process. It involves a closed-loop control, where optimal set-points can be automatically returned to the DCS to achieve closed-loop non-linear model predictive control. 
By running a test virtually, we saved a great deal of time and resources.
Niels Vandervoort, Senior Manager Pilot Plant Data & Systems at J&J Innovative Medicine
Optimizing and controlling the process in real-time reduces operator workload and minimizes operating costs by reducing either energy consumption, batch time, total solvent consumption, or a combination of the above factors realizing an efficient and sustainable process. Optimization of the solvent exchange process resulted in a 30% reduction in switch time and a 35% reduction in overall costs.
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