COURSE OVERVIEW:

The meaning of this course lies in the transformation of industrial chemistry from "Batch-and-Test" to real-time "Continuous Monitoring" through the implementation of Process Analytical Technology (PAT). In modern chemical and pharmaceutical manufacturing, waiting for laboratory results causes significant delays and increases the risk of producing out-of-specification material. This program provides the technical framework needed to integrate analytical chemistry directly into the production line, ensuring that quality is built into the process rather than tested after the fact.

The scope of the training focuses on the selection, installation, and validation of online analyzers, including NIR, Raman, and Fiber-Optic UV-Vis systems. It addresses the technical interface between the analyzer and the process stream, the management of "Sample Conditioning Systems" (SCS), and the role of "Chemometrics" in interpreting complex real-time data. Participants will explore the principles of "Quality by Design" (QbD) and how PAT serves as the critical feedback loop for automated process control systems (DCS/PLC).

The coverage includes a comprehensive investigation into the "Probe Fouling" challenges, the calibration of online sensors against laboratory reference methods, and the maintenance of analyzer houses in hazardous areas. The course emphasizes the reduction of "Process Variability" and the improvement of "Yield" through the use of multivariate data analysis. By mastering these PAT protocols, participants will be able to enable "Real-Time Release Testing" (RTRT) and drive the digital transformation of industrial chemical processes toward a "Factory of the Future."

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the core principles of PAT and its role in Quality by Design.
• Select the appropriate "Online Analyzer" for specific process streams.
• Design "Sample Conditioning Systems" (SCS) for representative data.
• Utilize "Near-Infrared" (NIR) and "Raman" probes for in-situ monitoring.
• Implement "Chemometric Models" (PCA/PLS) for multivariate data.
• Perform "Analyzer Calibration" against laboratory reference methods.
• Manage "Fiber-Optic" interfaces for remote analytical measurements.
• Troubleshoot "Probe Fouling" and "System Drift" in real-time.
• Integrate PAT data with "Distributed Control Systems" (DCS).
• Conduct "Validation" of online analyzers for regulatory compliance.
• Reduce "Cycle Time" through Real-Time Release Testing (RTRT).
• Lead the implementation of a PAT strategy in an industrial facility.

TARGET AUDIENCE:

This course is intended for Process Chemists, Automation Engineers, Quality Assurance Specialists, and Instrumental Technicians in the chemical and pharma sectors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.