Computational Fluid Dynamics (CFD)

Pharmaceutical R&D and Manufacturing Applications

Pharmaceutical Manufacturing

The pharmaceutical industry was one of the first to embrace the use of CFD and other sophisticated analysis tools to evaluate ventilation, manufacturing processes, cleanliness, and safety for their high tech manufacturing and R&D facilities. There are many unique aspects to this industry where the level of air quality control typically exceeds that of most other industries. For instance, the clean rooms in pharmaceutical plants usually need to be both aseptic and "particulate clean" simultaneously. The use of robotics, automation and sophisticated quality control is usually unmatched across the spectrum of industries.

Clean rooms are also regularly evaluated for their ability to control particulates either through standard brute-force ventilation methods or by clever design features that allow control with much less air flow. The pharmaceutical industry contains many clean rooms that are used for a plethora of applications such as lyophilization, flash freezing, vial filling, vial capping, mixing, fermentation, cell incubation, warehousing and many other applications. CFD is successfully used to aid in the evaluation of clean environments, as well as their air handling design, equipment layouts, and energy consumption.

What we do:

  • CFD evaluation of airflow, energy efficiency and safety of research labs.
  • Studies of airflow patterns and particulate loading in clean controlled environments.
  • Assessment flow fields around robotics, machines and Restricted Access Barriers (RABs).
  • Evaluation of clean and/or cold warehouse spaces.
  • CFD analysis of processes such as spraying, freezing, or filling.
  • Wind studies around manufacturing buildings, research labs and industrial complexes.
  • Studies of ventilation, safety and energy efficiency in lab animal holding rooms.
  • CFD assessments of procedure rooms used in comparative medicine.
  • Potent compound area safety analysis.

Spaces Modeled:

  • Aseptic clean rooms
  • Chemical laboratories
  • Manufacturing lines
  • Fermentation facilities
  • Vaccine production areas
  • Incubators
  • Robotic filling rooms
  • Autoclave areas
  • Clean and/or controlled temperature high-bay warehouses
  • Lyophilization areas
  • Lab animal facilities
  • Potent compound labs

Pharmaceutical R&D and Manufacturing Applications Examples:

(click on images to enlarge)

Streamlines of air patterns in a fermentation suite
Streamlines of air patterns in a fermentation suite
Velocity streamlines in a product packaging clean room
Velocity streamlines in a product packaging clean room
Streamlines in a clean drug filling area with restricted access barriers and robotics
Streamlines in a clean drug filling area with restricted access barriers and robotics
 
Streamlines in a Grade A robotic agitator
Streamlines in a Grade A robotic agitator