What this webinar covers

The emergence of system based modelling for pharmaceutical manufacturing processes is providing an opportunity to holistically model the influence material and process parameters on intermediate and end product quality attributes. These type of models are in effect a science-based digital twin of an entire manufacturing process. Development of digital twins for continuous direct compression and roller compaction processes are presented. These models can be used to simulate the entire process where the impact of changes and virtual experiments on tablet properties can be explored.

In a pharmaceutical development context, the aim of the digital twin is to facilitate lean process design, where a robust product and process can be developed and established without the waste associated with purely experimental trial and error approaches. Achieving this aim requires not only a model that is sufficiently predictive, but also one that is sufficiently usable by development scientists. Adequate engagement with the end-users, ensuring prioritisation of use cases and alignment of expectations has become critical to achieving business value from the digital twin concept.


Gavin Reynolds, AstraZeneca

Gavin Reynolds is a Senior Principal Scientist – Process Engineering and Digital, based within Pharmaceutical Technology and Development at AstraZeneca, Macclesfield and is also a Visiting Professor in the Department of Chemical and Biological Engineering at the University of Sheffield.

Following completion of a PhD in 2001, Gavin continued academic research as a post-doctoral research associate and then lecturer at the University of Sheffield. In 2006 he joined AstraZeneca to build the process engineering capability in Product Development. During his time at AstraZeneca he has led the Process Engineering capability network and is now strategically leading a new Modelling and Simulation capability build as well as implementing Digital Twins to enable accelerated development and scale-up of new pharmaceutical processes. Gavin is a chartered chemical engineer and a Fellow of the Institution of Chemical Engineers (IChemE). He has authored over 85 peer-reviewed publications with over 1600 citations.

Lily Worden, AstraZeneca

Lily Worden is a Global Graduate Associate on AstraZeneca’s Pharmaceutical Technology and Development Programme, Macclesfield. She joined AstraZeneca after completing a MChem Degree in Medicinal and Biological Chemistry from the University of Edinburgh. She is currently on a rotation within Modelling and Simulations, focusing on Deployment of Digital Twins within Product Development. Previous rotations have provided experience across analytical science, digital uplift and validation science.