Residence Time Distribution-Based Smith Predictor: an Advanced Feedback Control for Dead Time–Dominated Continuous Powder Blending Process

Abstract Purpose In continuous manufacturing (CM), the material traceability and process dynamics can be investigated by residence time distribution (RTD). Many of unit operations used in pharma industry were characterized dead time–dominated RTD. Even though feasible proper feedback control is one many advantages CM, its application challenging these cases. This study aims to develop a control, implementing RTD Smith predictor structure powder blender line. Methods Continuous blending was with near-infrared spectroscopy (NIR), controlled through volumetric feeder. A MATLAB GUI developed calculate concentration API based on chemometric evaluation spectra. The programmed changed feeding rate proportional integral derivative (PID) predictor, which implemented system. structures compared even system amplified time. Results this work, devised utilizing classic PI normal an increased able reduce response for various disturbances up 50%, had lower effect control. Conclusions Implementing models improved design further expanded wide range applications models. Both system; however, presented more reliable faster wider space tuning.