White paper
Digital energy monitoring for sustainable tableting processes.
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Reading time 5 min
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A study by
Introduction
The pharmaceutical tableting process represents one of the most critical and complex unit operations in solid dosage manufacturing, where mechanical, material and process variables converge to determine both product quality and process efficiency. Traditionally, the performance of tablet compression has been evaluated through conventional indicators such as output capacity, weight uniformity, mechanical strength, friability and Overall Equipment Effectiveness (OEE).
However, this traditional framework, while essential for ensuring compliance and product quality, provides only a partial representation of process performance. In recent years, the increasing emphasis on sustainability has given rise to a broader perspective, in which process efficiency is no longer defined solely in terms of productivity and quality, but also in terms of resource utilisation, energy consumption and environmental impact.
Within this evolving paradigm, pharmaceutical manufacturing is undergoing a profound transformation driven by digitalisation and Industry 4.0 principles.
Modern production systems are progressively transitioning toward interconnected, sensor-rich environments capable of real-time data acquisition, advanced analytics and process integration.
In this context, tablet presses are no longer purely mechanical devices but are becoming cyber-physical systems, where physical operations are tightly coupled with digital monitoring and control layers. This transformation enables the continuous acquisition of high-frequency process data, opening new opportunities for deeper process understanding, predictive control and sustainability-driven optimisation.
Among the various aspects of process performance, energy consumption plays a fundamental yet historically underexplored role. Tableting is intrinsically energy-dependent: each stage including powder feeding, die filling, compression and ejection requires precisely controlled energy transfer mechanisms that directly influence both process stability and final product quality.
The integration of advanced digital monitoring tools, such as the Energy Diary, brings about a fundamentally different approach. Rather than considering energy consumption as a passive indicator, the Energy Diary enables its transformation into an active, machine-level process variable, continuously recorded, contextualised and correlated with operational parameters.
The availability of real-time, high-resolution energy data also supports the transition toward data-driven and predictive manufacturing strategies. Advanced analytics applied to energy signals can reveal process drifts, identify inefficient operating conditions, and enable predictive maintenance strategies aimed at minimising downtime and reducing resource waste.
Within this framework, the DOMINA 500 tablet press, equipped with an integrated Energy Diary system, represents a significant advancement in the evolution of pharmaceutical manufacturing technologies. By embedding energy monitoring capabilities directly within the process control architecture, the system enables continuous, contextualised and actionable insight into the energetic behaviour of the compression process.
Energy Diary digital architecture
The energy diary is embedded within the machine HMI and accessible through the taskboard interface. It integrates functions for real-time monitoring, historical analysis, sensor calibration and structured data export, positioning energy monitoring at the core of process governance.
Beyond operational optimisation, the integration of energy monitoring at a machine level provides a robust foundation for quantitative sustainability assessment.
The ability to measure, attribute and analyse energy consumption in relation to specific batches, operating conditions and machine states enables a more accurate estimation of environmental indicators, including carbon footprint and energy efficiency KPIs.
Energy efficiency KPIs monitoring and time-resolved energy dynamics
The system continuously measures electrical consumption at machine level, expressed in kW and normalised against calibrated operational limits. This enables identification of non-optimal energy conditions and supports immediate corrective actions.
This conceptual shift is particularly relevant within the frameworks of Quality by Design (QbD) and Process Analytical Technology (PAT). In these paradigms, process understanding is achieved through the identification and continuous monitoring of Critical Process Parameters (CPPs). By incorporating energy consumption into this framework, it becomes possible to establish multidimensional relationships between process dynamics, machine behaviour and resource efficiency.
Batch-level energy analysis
Time-series visualisation provides insight into the evolution of energy consumption during operation. Stable profiles indicate robust process conditions, whereas deviations reflect disturbances, inefficiencies or system-level events.
Energy data can be correlated with specific production batches, enabling evaluation of energy consumption at product level.
This allows comparative analysis between operating conditions and supports the optimisation of process parameters.
Sensor calibration and data integrity
The Energy Diary includes sensor linearisation and calibration tools to ensure accurate measurement. This guarantees that energy data reflects actual machine behaviour, supporting reliable process modelling and optimisation.
Sustainability impact and conclusions
The integration of the Energy Diary enables a paradigm shift in sustainability, where energy becomes a controllable variable integrated within process design. Key contributions include:
• Identification and elimination of non-value-added energy consumption.
• Optimisation of operating conditions through real-time feedback.
• Correlation between energy use and process parameters.
• Support for predictive maintenance and reduced downtime.
• Enhanced capability for carbon footprint tracking and sustainability KPI definition
This approach enables a transition from passive energy monitoring to active energy optimisation.
Conclusion
The DOMINA 500 redefines sustainability in tablet compression by embedding energy monitoring within process control. Through the Energy Diary, energy becomes a measurable, correlated and optimisable variable, enabling improved efficiency, reduced environmental impact and enhanced process understanding. Ultimately, the convergence of process science, digitalisation and energy monitoring redefines tablet compression as an energy-aware, intelligent and sustainable manufacturing operation, positioning DOMINA 500 as a key enabling technology for the next generation of pharmaceutical production systems.
New
On show
Tableting
Up to 576,000 tabs/h
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