Optimization of fluid bed dryer energy consumption for pharmaceutical drug processes through machine learning and cloud computing technologies
- Autores: Roberto Barriga Rodríguez
- Directores de la Tesis: Houcine Hassan (dir. tes.)
- Lectura: En la Universitat Politècnica de València ( España ) en 2023
- Idioma: inglés
- Tribunal Calificador de la Tesis: Manuel Jose Perez Malumbres (presid.), Juan Miguel Martínez Rubio (secret.), Antonio Jimeno Morenilla (voc.)
- Programa de doctorado: Programa de Doctorado en Informática por la Universitat Politècnica de València
- Materias:
- Enlaces
- Tesis en acceso abierto en: RiuNet
- Resumen
High energy costs, the constant regulatory measures applied by administrations to maintain low healthcare costs, and the changes in healthcare regulations introduced in recent years have all significantly impacted the pharmaceutical and healthcare industry. The industry 4.0 paradigm encompasses changes in the traditional production model of the pharmaceutical industry with the inclusion of technologies beyond traditional automation. The primary goal is to achieve more cost-efficient drugs through the optimal incorporation of technologies such as advanced analytics. The manufacturing process of the pharmaceutical industry has different stages (mixing, drying, compacting, coating, packaging, etc..), and one of the most energy-expensive stages is the drying process. This process aims to extract the liquid content, such as water, by injecting warm and dry air into the system. This drying procedure time usually is predetermined and depends on the volume and the kind of units of a pharmaceutical product that must be dehydrated. On the other hand, the preheating phase can vary depending on various parameters, such as the operator's experience. It is, therefore, safe to assume that optimization of this process through advanced analytics is possible and can have a significant cost-reducing effect on the whole manufacturing process. Due to the high cost of the machinery involved in the drug production process, it is common practice in the pharmaceutical industry to try to maximize the useful life of these machines, which are not equipped with the latest sensors. Thus, a machine learning model using advanced analytics platforms, such as cloud computing, can be implemented to analyze potential energy consumption savings. This thesis is focused on improving the energy consumption in the preheating process of a fluid bed dryer by defining and implementing an IIOT (Industrial Internet of Things) Cloud computing platform. This architecture will host and run a machine learning algorithm based on Catboost modeling to predict when the optimum time is reached to stop the process, reduce its duration, and consequently its energy consumption. Experimental results show that it is possible to reduce the preheating process by 45% of its time duration, consequently reducing energy consumption by up to 2.8 MWh per year.
