XPS - eXtended Particle Simulations
for Pharmaceutical Manufacturing
XPS at a Glance
XPS (eXtended Particle Simulations) is cutting-edge particle simulation software designed specifically for pharmaceutical manufacturing and development.
It uses the Discrete Element Method (DEM) with advanced contact models and GPU-optimized algorithms to simulate granular flow and particle-based processes at unmatched speed and accuracy. XPS helps you to understand failures, optimize processes, and design control strategies – accelerating critical business decisions while reducing risk in product and process development.
Developed by RCPE and delivered by InSilicoTrials, XPS brings high-end DEM and CFD DEM simulation capability directly into your pharma R&D and manufacturing workflows, on desktop workstations or in the cloud.
Why Use XPS in Pharmaceutical Process Development?
Understanding granular flow and particle behavior is vital in many pharmaceutical unit operations, from blending to tablet coating and fluidized bed processing. XPS turns these complex systems into a virtual testbed for pharmaceutical engineering, allowing you to evaluate process designs and parameters before running costly experiments or plant trials.
Key Benefits
Accelerate innovation
Rapidly screen process concepts and operating conditions using ultra fast GPU accelerated DEM simulations.
Minimize risk
Predict spray distribution, coating efficiency, blend uniformity, and critical force distributions before scale-up.
Optimize efficiency and robustness
Reduce experimentation, avoid over‑blending and segregation, and support Quality by Design (QbD) and digital twin initiatives.
Enable datadriven decisions
Use highfidelity simulation data to support technology transfer, scaleup, and regulatory documentation.
Support troubleshooting
Identify root causes of processing issues and enable targeted troubleshooting for pharmaceutical applications.
Improve process understanding
Gain a deeper understanding of complex production processes and particle interactions across unit operations.
Core Pharmaceutical Applications of XPS Software
XPS is tailored to pharmaceutical solids processing and directly addresses common challenges in oral solid dosage manufacturing.
Tablet Coating
Tablet coating is critical for product performance and appearance. XPS enables tablet coating simulations that account for various tablet shapes and complex coater geometries.
With XPS you can:
- Predict coating distribution and spray drying behavior based on nozzle parameters.
- Analyze coating thickness uniformity, coefficient of variation (CoV), spray losses, and cycle time.
- Evaluate force distributions related to chipping, twinning, and mechanical stress on tablets.
Powder Blending and Mixing
Blending cohesive and free flowing powders into a homogeneous mixture is a key challenge in solid oral dosage form production. XPS helps you understand granular mixing behavior in blenders and charging systems.
With XPS you can:
- Study the impact of filling level, batch mass, and operating conditions on blend homogeneity.
- Optimize charging scenarios and equipment configurations.
- Reduce the risk of over blending, over lubrication, and segregation to improve process robustness.
CFD - DEM coupling
Modeling gas-solid applications such as fluidized beds requires accurate CFD-DEM simulations. XPS provides coupling with the powerful AVL FIRE™ M CFd solver for high-fidelity simulations.
With XPS CFD coupling you can:
- Analyze coating, mixing, temperature distributions, and residence times.
- Investigate particle-fluid interactions with advanced heat and mass transfer models.
- Design and optimize more efficient, stable, and scalable fluidized bed processes.
OpenFOAM coupling via the open-source preCICE library will be available in fall 2026.
XPS Features that Support Pharmaceutical R&D Teams
XPS combines high physical fidelity with maximum computational performance and is designed for pharmaceutical scientists, process engineers, and formulation teams – not only simulation specialists.
Simulation Engine
- Discrete Element Method (DEM) with advanced contact models to capture bulk behavior realistically.
- Massively parallel, native CUDA implementation running on NVIDIA GPUs for ultra-fast execution.
- Handles many millions of particles and complex geometries (STL, clumps, multi-sphere particles, tablets).
User Experience
- Fully developed graphical user interface (GUI)
- Intuitive handling of complex geometries (STL import) and large particle counts
- Built-in post-processing tools and support for analyzing simulation results
Performance & Platforms
- Optimized to drastically reduce computational demand per time step and memory consumption
- Runs on standard workstations with up to 4 GPUs, one simulation per GPU
- Supports Windows, Linux, and cloud deployments
Get in touch
XPS is developed by RCPE and delivered by InSilicoTrials
For demos, licensing, or collaboration opportunities contact
- Sulaiman Mohsenzada, RCPE Deputy Director
- Partner: InSilicoTrials
We are happy to discuss how XPS can support your projects – from early development to commercial manufacturing.
We offer dedicated options for academic users – get in touch to discuss free trial access and collaborative research opportunities.
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