What's included?

15% Faster Freeze Drying and 50% Less Downtime with AI Optimization
Life Sciences

15% Faster Freeze Drying and 50% Less Downtime with AI Optimization

Explore the Results

See how AI optimization for freeze drying improved efficiency and reduced waste

Key Results Delivered

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faster freeze-drying cycle time

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reduction in unplanned downtime

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decrease in energy consumption

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increase in product throughput

About The Client

A global vaccine manufacturer operating high-volume lyophilization units to produce sensitive biologics. The company sought to reduce energy use and drying time while improving product consistency through AI optimization for freeze drying and predictive analytics for lyophilization.
Company

Industry:

Life Sciences

Location:

USA

Freeze Drying Bottlenecks

Extended freeze-drying cycles and aging equipment limited throughput and increased operating costs. The manufacturer lacked real-time insight into failures and required a better method for lyophilization cycle development optimization to reduce product risk and delays.

Long drying cycles impacted throughput and energy

Frequent freeze dryer failure created downtime

No predictive analytics for lyophilization issues

Inflexible cycles due to fixed drying recipes

Our Solution

Quartic deployed predictive analytics for lyophilization by contextualizing batch, equipment, and process data. The system enabled AI optimization for freeze drying and real-time cycle adjustment, leading to optimized drying recipes and fewer equipment failures.

Solutions We Have Provided

  • Built baseline models for freeze-drying cycle optimization
  • Delivered AI-driven cycle tuning for every batch
  • Enabled predictive maintenance to reduce unplanned downtime
Solution Dashboard

Results & Benefits - Optimized Freeze Drying with Tangible Impact

The manufacturer reduced drying cycle time by 15% and energy usage by 23%. Predictive maintenance halved unplanned downtime. Overall product throughput improved by 5%, leading to reduced cost and higher manufacturing agility.

Results

Smarter Cycles, Less Downtime

iLuminator Icon

iLuminator

Unified contextual data from freeze dryers and batch records.

iLuminator Screenshot
eXponence Icon

eXponence

Enabled predictive analytics for lyophilization cycles and performance modeling.

eXponence Screenshot
Process Optimizer Icon

Process Optimizer

Delivered setpoint recommendations for lyophilization cycle development optimization.

Process Optimizer Screenshot

Quartic helped us tune our freeze drying process for both speed and stability. What used to take weeks to refine is now optimized in real time.

Global Head of Manufacturing Science Vaccine Division

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