Analyzing the Mixing Dynamics of an Industrial Batch Bin Blender via Discrete Element Modeling Method

A discrete element model (DEM) has been developed for an industrial batch bin blender in which three different types of materials are mixed. The mixing dynamics have been evaluated from a model-based study with respect to the blend critical quality attributes (CQAs) which are relative standard deviation (RSD) and segregation intensity. In the actual industrial setup, a sensor mounted on the blender lid is used to determine the blend composition in this region. A model-based analysis has been used to understand the mixing efficiency in the other zones inside the blender and to determine if the data obtained near the blender-lid region are able to provide a good representation of the overall blend quality. Sub-optimal mixing zones have been identified and other potential sampling locations have been investigated in order to obtain a good approximation of the blend variability. The model has been used to study how the mixing efficiency can be improved by varying the key processing parameters, i.e., blender RPM/speed, fill level/volume and loading order. Both segregation intensity and RSD reduce at a lower fill level and higher blender RPM and are a function of the mixing time. This work demonstrates the use of a model-based approach to improve process knowledge regarding a pharmaceutical mixing process. The model can be used to acquire qualitative information about the influence of different critical process parameters and equipment geometry on the mixing dynamics.