Influence of Material Properties and Process Parameters on Residence Time Distribution in a Tablet Feed Frame: A Numerical Study
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The residence time distribution (RTD) in a tablet feed frame is critical for ensuring blend uniformity and product quality in pharmaceutical manufacturing. While previous studies have explored RTD experimentally in different units, a numerical investigation linking the RTD to material properties and process parameters remains an open challenge. In this work, we employ an intelligent sampling approach on a numerical database generated using the Luding contact model to systematically evaluate the influence of material attributes - such as shear, compression, dynamic angle of repose, and packing - as well as process parameters on RTD. Our simulation-based methodology provides novel insights into the interplay between material behavior and process conditions, offering a predictive framework for optimizing feed frame performance. The results highlight key factors governing RTD variability, bridging a critical gap between material characterization and process control in continuous tablet manufacturing. The insights gained from this study can be applied both numerically and experimentally. Numerically, they aid in selecting the most relevant material characterization tests for model calibration. Experimentally, they provide a basis for assessing how material property variations influence feed frame performance.