Intelimek

Digital Twins for Unit Operations

At Intelimek, we are transforming pharmaceutical manufacturing by offering a complete Software-as-a-Service (SaaS) solution that integrates advanced Digital Twin technology with comprehensive support services. Our offering isn’t just a digital twin platform—it’s a full-service web application that performs high-fidelity simulations, AI/ML model training, and process optimization across critical unit operations such as blending, granulation,film coating, drying, direct compaction. By combining state-of-the-art simulation techniques (FEA, DEM, CFD) with AI, cloud-based processing and expert services, we help you enhance process efficiency, reduce waste, and ensure the highest product quality.

Harnessing Physics and AI for Superior Process Engineering

Our Digital Twin serves as a dynamic, virtual replica of your manufacturing processes.
It continuously integrates real-time production data, laboratory results, historical insights
and physics-based process models to deliver actionable intelligence.

Core Values

Consistent Process Quality

Ensure uniform mixing, coating, and granulation for superior quality and reduced variability.

Cost-Efficient Operations

Lower material, energy, and operational costs with AI-driven process optimization.

Seamless
Scale-Up

Accelerate R&D to production with fewer trials and reduced scale-up risks.

Compliance and Assurance

Meet FDA and EMA standards to build regulatory trust and ensure product quality.

Technology Simplified and Democratized

Enable easy adoption, standardize best practices, and empower teams with consistent, scalable technology.

Why Intelimek?

Intelimek combines deep domain expertise in pharmaceutical manufacturing with advanced AI-driven process optimization. Our solutions are purpose-built to tackle industry challenges—ensuring consistent quality, reducing costs, and accelerating scale-up.

With years of experience delivering scalable, compliant, and production-ready systems, Intelimek empowers pharma companies to adopt smart manufacturing with confidence. We simplify complex technologies, enabling teams to work more efficiently, achieve regulatory compliance, and unlock sustainable value across the enterprise.

Industry Challenges Intelimek Solutions
Data Integration Complexity

Merging real-time production, sensor, and historical batch data is difficult and time-consuming
Unified Data Pipeline

Our SaaS platform aggregates, cleanses, and visualizes multi-source data for real-time process insights.
Model Calibration Needs

Accurate modeling of blending, granulation, and coating demands precise calibration and validation.
Robust Model Calibration

ML-driven experiments and advanced techniques ensure reliable, physics-aligned, customized process models.
High Computational Demand

Detailed simulations like DEM and CFD require significant computing resources and expertise.
Scalable Cloud Simulations

Cloud HPC and AI-based surrogate models deliver fast, scalable simulations—no local infrastructure needed.
Specialized Expertise Required

Advanced modeling tools can be hard to adopt without specialized knowledge or training.

User-Friendly Platform & Training

Guided workflows and expert-led programs empower teams to leverage AI, DEM, and CFD models.
Regulatory & Cost Barriers

High costs and regulatory challenges slow digital adoption in pharma manufacturing.
Compliance-Ready SaaS Solution

FDA/EMA-compliant frameworks ensure smooth, cost-effective adoption with strong ROI.

Industry Challenges

  • Data Integration Complexity

    Merging real-time production, sensor, and historical batch data is difficult and time-consuming

  • Model Calibration Needs

    Accurate modeling of blending, granulation, and coating demands precise calibration and validation.

  • High Computational Demand

    Detailed simulations like DEM and CFD require significant computing resources and expertise.

  • Specialized Expertise Required

    Advanced modeling tools can be hard to adopt without specialized knowledge or training.

  • Regulatory & Cost Barriers

    High costs and regulatory challenges slow digital adoption in pharma manufacturing.

Intelimek Solutions

  • Unified Data Pipeline

    Our SaaS platform aggregates, cleanses, and visualizes multi-source data for real-time process insights.

  • Robust Model Calibration

    ML-driven experiments and advanced techniques ensure reliable, physics-aligned, customized process models.

  • Scalable Cloud Simulations

    Cloud HPC and AI-based surrogate models deliver fast, scalable simulations—no local infrastructure needed.

  • User-Friendly Platform & Training

    Guided workflows and expert-led programs empower teams to leverage AI, DEM, and CFD models.

  • Compliance-Ready SaaS Solution

    FDA/EMA-compliant frameworks ensure smooth, cost-effective adoption with strong ROI.

How Intelimek’s Digital Twin SaaS Works

Our solution is designed to integrate seamlessly into your manufacturing operations through a three-step approach:

Material Characterization & Model Setup

Experimental Calibration

We calibrate material properties using advanced techniques (e.g., rotating drum with machine vision) tailored for your specific processes.

AI-Driven Analysis

Our service analyzes key parameters—such as particle size distributions for blending and spray dynamics for coating—to build robust simulation models.

  • Detection of powder bed from the captured video of dynamic angle of repose test using rotating drum
  • Image processing for the powder bed profile
  • Calibration of powder properties using machine learning

Simulation & Process Optimization

Process-Specific Simulation:

Blending
Coating

Democratization of Simulations

Automation of Solvers: We automate the process modeling strategy within the solver by tuning the models for the operating range of the parameters

Deployment as Web Apps: Automated process models are deployed as Web Apps including simulation data management and post processing.

Quick Insights with AI

Machine Learning Models: Generation of insights from simulation tales time due to computational time. We develop Reliable AI models from simulations data for quick predictions

Insights from Various Data Sources: We leverage the data from simulations, experiments, actual process parameters and sensors data to develop comprehensive machine learning models

Comprehensive Digital Twins
Real-Time Monitoring & Predictive Control

Live Data Integration

Our web application connects directly with manufacturing sensors, providing real-time monitoring and control across all unit operations.

Adaptive Process Adjustments

AI-based recommendations enable batch-to-batch adjustments, ensuring consistent quality.

Continuous Improvement

The Digital Twin continuously updates with live production data, driving long-term process optimization as part of our ongoing service support.

Ready to Transform Your Manufacturing Process?

Contact us today to discover how our all-in-one SaaS solution can propel your operations into the future.

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At Intelimek, our mission is to “Inteligize the Making,” a commitment to transforming the manufacturing industry through innovative technology and deep expertise

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Our Services
Contact Details

Intelimek LLC
111 Middlesex Turnpike #1051 Burlington,
MA 01803 United States

+91 987 654 3210

consult@intelimek.com

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