USE Cases
Crystallization Optimization: Reduce Process Time by 75%
Monitor crystal size and shape in real-time to improve yield, quality, and energy efficiency
Pharmaceutical production
Optimizing processing time through real-time monitoring of crystal size and shape is essential, as efficient crystallization directly impacts yield, product quality, and energy consumption in modern pharmaceutical manufacturing
Findings
- Monitoring 5 batch operations revealed:
- Yield and crystal size reaches maximum after 1 hour
- After 1 hour, crystals start to break due to shear force from stirrer
Actions
Based on findings it was possible to reduce crystallization time by 76% which increased throughput and energy efficiency. Optimizing the parameters caused less variation among batches
- Energy reduction
- Time reduction
- Improvement of product quality
Process Deviation Detection: Prevent Product Loss in Real-Time
Monitor crystal size distribution to maintain throughput and product quality
Sugar production
Deviations in process conditions and resulting product loss can often be avoided by implementing real-time monitoring. In this case, ParticleTech Solution identified abnormal crystal size distribution in one of the crystallization units, enabling immediate intervention to prevent product loss and improve throughput
Findings
ParticleTech Solution showed that the crystal size distribution in one of the crystallization units deviated from the rest
Actions
The information made it possible to react to the deviating process, prevent loss of product and increase throughput
- Energy reduction
- Higher throughput (faster growth)
- Higher product quality (bigger crystals)
Centrifuge Optimization: Reduce Biomass Loss by 36%
Automated particle analysis helps fine-tune decanter settings for higher yield and lower waste
Biomanufacturing
Biomass separation is a key factor in product loss during biomanufacturing. ParticleTech’s automated segmentation of biomass and crystals across feed, light, and heavy phase streams enables precise monitoring and real-time adjustment of decanter settings
Findings
The biomass-crystal segmentation algorithm enables direct measurements of the biomass/crystals distribution
Actions
ParticleTech Solution made it possible to reduce loss of product in the decanter centrifuge by 36%!
- Reduction of loss
- Energy reduction
- Higher throughput
Flocculation Optimization: Reduce Raw Material Use
Real-time particle monitoring enables accurate polymer dosage for better clarification and lower waste
Biomanufacturing
Dosage of flocculants to processes is critical for ensuring a good clarification. ParticleTech Solution can be used to analyse before and after a flocculation to find the optimal polymer dosage
Findings
Flocculation effeciency was quantified by measuring the quantity of particles smaller than 10µm after flocculation
Actions
The Solution enabled a direct optimization of the ploymer dosage vs. flocculation efficiency
- Optimal Polymer Dosage
- Reduction of Loss
- Increased Flocculation Efficiency
Dissolution Profiling for Better Tablet Performance
Automated particle monitoring improves formulation and ensures therapeutic consistency
Pharmaceutical production
The dissolution rate of tablets is key to their bioavailability and therapeutic effectiveness. ParticleTech enables automated analysis of particle size and shape during USP-standard dissolution tests, delivering real-time data to support optimal formulation and consistent product quality.
Findings
Automatic sampling from standard USP dissolution vessels provide data on dissolution rates of particles in suspension etc.
Actions
Dissolution rates can subsequently be used to find the optimal product formulation
- Optimal Product Formulation
- Quality Control
Fermentation Monitoring for Better Biomass Control
Real-time cell cluster analysis enables smarter feeding and process optimization
Biomanufacturing: Continuous monitoring of fermentation process
Biomass concentration is a key parameter for characterizing and controlling fermentation processes. ParticleTech enables continuous, real-time measurement of biomass levels, allowing for precise optimization of feeding rates. In yeast fermentations, the solution also provides detailed insights into budding cell distribution—ensuring tighter process control even in the presence of insoluble particles within the fermentation broth
- Real-time monitoring of biomass concentration
- Optimized fermentation feeding strategies
- Distribution analysis of budding cells