Investigating screw-agitator speed ratio impact on feeding performance in pharmaceutical manufacturing using discrete element method.

In continuous powder handling processes, precise and consistent feeding is crucial for ensuring the quality of the final product. The intermixing effect caused by agitators, which alters the powder's bulk density, flow rate, and flow patterns, plays a significant role in this process, yet it is often overlooked. This study combines discrete element method (DEM) modeling and experiments using a commercial-scale feeder to propose a Digital Twin (DT) framework. The DEM model accurately captures key flow features, such as bypass trajectories, stagnant zones, and preferential flow patterns, while providing quantitative predictions for the feed factor and zones prone to material accumulation. Scenario analysis is performed to identify the most favorable operating ranges of the screw-agitator ratio and screw speed, considering the cohesive properties of the powder. The study demonstrates that powders with poor flow characteristics require tighter operational constraints, as the screw-agitator ratio is susceptible to variations in mass feed rate. This contribution highlights the importance of selecting an appropriate screw-agitator ratio instead of maintaining a fixed value. Properly choosing this ratio helps determine an optimal operation window, which aims to achieve a minimum agitation level needed to induce unhindered flow and reduce variability in the mass flow rate.