Optimize blending, granulation, film coating, and more with Intelimek’s AI enabled cloud based process engineering solutions
AI + Physics: Revolutionizing Pharmaceutical Manufacturing with Digital Twin Solutions
Digital Twins for Unit Operations
At Intelimek, we are transforming pharmaceutical manufacturing by offering a complete Software-as-a-Service (SaaS) solution that integrates advanced Digital Twin technology with comprehensive support services. Our offering isn’t just a digital twin platform—it’s a full-service web application that performs high-fidelity simulations, AI/ML model training, and process optimization across critical unit operations such as blending, granulation,film coating, drying, direct compaction. By combining state-of-the-art simulation techniques (FEA, DEM, CFD) with AI, cloud-based processing and expert services, we help you enhance process efficiency, reduce waste, and ensure the highest product quality.
Harnessing Physics and AI for Superior Process Engineering
Our Digital Twin serves as a dynamic, virtual replica of your manufacturing processes. It continuously integrates real-time production data, laboratory results, historical insights and physics-based process models to deliver actionable intelligence.
Our Value
Consistent Process Quality
Ensure uniform mixing, coating, and granulation for superior quality and reduced variability.
Cost-Efficient Operations
Lower material, energy, and operational costs with AI-driven process optimization.
Seamless Scale-Up
Accelerate R&D to production with fewer trials and reduced scale-up risks.
Compliance and Assurance
Meet FDA and EMA standards to build regulatory trust and ensure product quality.
Technology Simplified and Democratized
Enable easy adoption, standardize best practices, and empower teams with consistent, scalable technology.
Why Intelimek
Intelimek combines deep domain expertise in pharmaceutical manufacturing with advanced AI-driven process optimization. Our solutions are purpose-built to tackle industry challenges—ensuring consistent quality, reducing costs, and accelerating scale-up.
With years of experience delivering scalable, compliant, and production-ready systems, Intelimek empowers pharma companies to adopt smart manufacturing with confidence. We simplify complex technologies, enabling teams to work more efficiently, achieve regulatory compliance, and unlock sustainable value across the enterprise.
Industry Challenges |
Intelimek Solutions |
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Merging real-time production, sensor, and historical batch data is difficult and time-consuming |
Our SaaS platform aggregates, cleanses, and visualizes multi-source data for real-time process insights. |
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Accurate modeling of blending, granulation, and coating demands precise calibration and validation. |
ML-driven experiments and advanced techniques ensure reliable, physics-aligned, customized process models. |
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Detailed simulations like DEM and CFD require significant computing resources and expertise. |
Cloud HPC and AI-based surrogate models deliver fast, scalable simulations—no local infrastructure needed. |
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Advanced modeling tools can be hard to adopt without specialized knowledge or training. |
Guided workflows and expert-led programs empower teams to leverage AI, DEM, and CFD models. |
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High costs and regulatory challenges slow digital adoption in pharma manufacturing. |
FDA/EMA-compliant frameworks ensure smooth, cost-effective adoption with strong ROI. |
How Intelimek’s Digital Twin SaaS Works
Our solution is designed to integrate seamlessly into your manufacturing operations through a three-step approach:
Material Characterization & Model Setup
- Experimental Calibration: We calibrate material properties using advanced techniques (e.g., rotating drum with machine vision) tailored for your specific processes.
- AI-Driven Analysis: Our service analyzes key parameters—such as particle size distributions for blending and spray dynamics for coating—to build robust simulation models.
Simulation & Process Optimization
Process-Specific Simulation:
- Blending: DEM simulations predict particle interactions and mixing uniformity
- Film Coating: CFD models capture airflow, drying, and spray dispersion for even coating application.
- Granulation: Simulations optimize agglomeration and drying dynamics for superior granule formation.
Blending
Coating
Democratization of Simulations
- Automation of Solvers: We automate the process modeling strategy within the solver by tuning the models for the operating range of the parameters
- Deployment as Web Apps: Automated process models are deployed as Web Apps including simulation data management and post processing.
This provides easy access to process performance & prediction insights for the users across the enterprise
Quick Insights with AI
- Machine Learning Models: Generation of insights from simulation tales time due to computational time. We develop Reliable AI models from simulations data for quick predictions
- Insights from Various Data Sources: We leverage the data from simulations, experiments, actual process parameters and sensors data to develop comprehensive machine learning models
Comprehensive Digital Twins - Real-Time Monitoring & Predictive Control
- Live Data Integration:
Our web application connects directly with manufacturing sensors, providing real-time monitoring and control across all unit operations. - Adaptive Process Adjustments:
AI-based recommendations enable batch-to-batch adjustments, ensuring consistent quality. - Continuous Improvement:
The Digital Twin continuously updates with live production data, driving long-term process optimization as part of our ongoing service support.
Intelimek’s comprehensive Digital Twin SaaS is not just a standalone platform—it’s a complete service offering that integrates advanced simulations, AI/ML model training, and a user-friendly web application to transform pharmaceutical manufacturing. By leveraging our solution, you can achieve unprecedented process optimization, cost efficiency, and quality compliance across blending, granulation, film coating, drying, direct compaction and beyond.
Ready to Transform Your Manufacturing Process?
Contact us today to discover how our all-in-one SaaS solution can propel your operations into the future.