CUSUM analysis of Fluidised Bed Dryer of Continuous Pharma Tablet Line

Pharmaceutical companies are increasingly dedicated to reducing energy consumption and enhancing sustainability to meet net-zero emissions targets. Achieving these objectives involves substantial research and development efforts. Digital Twins (DT) and Industry 4.0 technologies offer significant potential to optimise processes, improving both cost-effectiveness and sustainability.

This study integrates energy management techniques and statistical analysis within a Digital Twin framework, aiming to enhance process sustainability without compromising product quality. We examine a semi-continuous fluidised bed dryer (FBD) unit incorporated into a GEA Consigma-25 pharmaceutical manufacturing line at the Diamond Pilot Plant (DiPP), University of Sheffield. Experimental energy consumption data from the dryer, combined with digital twin data, were analysed using the Cumulative Sum (CUSUM) deviation method to identify areas of potential energy savings. A novel Energy Performance Indicator (EnPI) for the FBD is proposed to monitor product moisture content against energy usage. The analysis revealed that maintaining drying air temperature at 60°C delivered better-than-expected energy efficiency, even when the liquid-to-solid ratio varied from 0.18 to 0.3.

The integration of digital twin technology with CUSUM analysis proved effective for reviewing energy performance changes, allowing precise determination of energy targets that balance efficiency and product quality.