Aavis makes solid-dose pharmaceuticals; the project sat in the granulation and coating suite, where a shared process-air system supplies compressed, heated air to multiple unit operations at once.
Built an Aspen Plus model of the compression, heating, and stream-mixing network, running it across 5 scale-up scenarios to map temperature, pressure, and flow demand for a lab-to-pilot scale-up, cutting projected utility consumption 10%.
Isolated 4 repeatable root causes of yield and particle-size deviation across 50+ formulation runs and 8 product types using regression and PivotTables in Excel, raising batch yield 11% and reducing variability.
Supported a completed technology transfer to pilot scale by authoring 5 GMP-compliant SOPs and technical reports tying simulation outputs back to experimental data for the audit trail.
On the production floor at Aavis, next to the rotary tablet press.
