Role of Pellet Size, Shape, and Filling Method in Achieving Fill Weight Uniformity for Encapsulated Pelletized Systems: A Comparison of Experiment and Computer Simulation

Correlations between experimental filling and computer simulation for real pelletized systems were evaluated in this study. Simulations were successful in predicting the fill weight variability of a variety of pellet sizes and shapes and demonstrated similar values and trends to those observed experimentally. Simulation also helped identifying the critical variables affecting filling consistency such as pellet attributes and filling methods. Unit filling and automatic filling were found to be more comparable to simulation whilst manual flood filling appeared to lack reproducibility. Computer simulation can therefore be used as a method for predicting fill weight variability for different pellet fractions filled using different filling methods, which can facilitate process control and assurance of product quality. © 2009 Wiley‐Liss, Inc. and the American Pharmacists Association J Pharm Sci 99: 1299-1308, 2010