Digital Energy Monitoring for Sustainable Tableting Processes

The pharmaceutical tableting process is a mechanically complex and energy-dependent unit operation in solid dosage manufacturing. Traditionally, process performance has been evaluated through conventional indicators such as output capacity, weight uniformity, mechanical strength, friability, and Overall Equipment Effectiveness (OEE). However, this framework provides only a partial representation of process performance, particularly with respect to resource utilisation and environmental impact.This paper examines the integration of real-time energy monitoring within the tablet compression process, using the DOMINA 500 tablet press (IMA Active, Italy) as a case study. The DOMINA 500 is equipped with an integrated Energy Diary system that enables continuous, contextualised measurement of electrical energy consumption at machine level, expressed in kilowatts (kW) and normalised against calibrated operational limits. The analysis discusses how energy consumption, traditionally treated as a passive operational cost, can be repositioned as an active, machine-level process performance indicator within the frameworks of Quality by Design (QbD) and Process Analytical Technology (PAT). Where a relationship with Critical Quality Attributes (CQAs) is demonstrated, energy-related variables may also contribute to the identification and monitoring of Critical Process Parameters (CPPs). The Energy Diary architecture integrates real-time monitoring, historical trend analysis, sensor calibration tools, and structured data export, supporting both operational optimisation and quantitative sustainability assessment. Key contributions include: (i) the identification of non-value-added energy consumption through time-resolved energy dynamics; (ii) the correlation between energy profiles and specific production batches, enabling product-level energy attribution; (iii) support for condition monitoring and the development of predictive maintenance strategies; and (iv) a stronger basis for estimating carbon-related indicators and defining energy efficiency Key Performance Indicators (KPIs).This work contributes to the evolving paradigm of energy-aware, intelligent pharmaceutical manufacturing, where digitalisation, process science, and sustainability converge to redefine tablet compression as a controllable and optimisable operation.