Empowering Customer Process Excellence: The Complete Guide to the IMA Active Competence Center E-Learning Academy

SPONSORED CONTENT: The IMA Active Competence Center Academy is a comprehensive e-learning platform that helps pharmaceutical manufacturers build expertise in solid dose production. Going beyond equipment training, it combines process theory, machine knowledge and troubleshooting to improve operational excellence, accelerate onboarding and preserve critical know-how.

The IMA Active Competence Center Academy is a comprehensive digital learning ecosystem designed to transfer high-level pharmaceutical process expertise directly to customers. More than a traditional e-learning platform, the Academy represents a strategic knowledge transfer initiative aimed at strengthening operational autonomy, accelerating onboarding and preserving process know-how across solid dose manufacturing environments.

Figure 1: presentation of IMA’s virtual, instructor-led process training.

1. Strategic vision and educational philosophy

The Academy has been conceived with a clear strategic objective: to ensure that customers not only operate IMA Active equipment efficiently, but deeply understand the scientific, technological and process principles behind it. This approach transforms training from basic operational instruction into structured competence development.

By embedding process theory, machine design logic, parameter interaction and troubleshooting methodology into a single digital pathway, the Academy supports companies facing common industry challenges such as workforce turnover, retirement of experienced operators, globalisation of production sites and the need for rapid qualification of new hires.

2. Platform architecture and learning structure

The Competence Center Academy is organised into four core process training programs:

• Granulation

• Compression

• Capsule Filling

• Coating

Figure 2: IMA Active e-learning platform for process training.

Each training program follows a standardised structure to ensure consistency and ease of navigation. The learner is guided through clearly defined chapters, some of them marked as mandatory when completion is required to access the final questionnaire. This guarantees that foundational knowledge is consolidated before moving on to advanced topics.

Figure 3: example of complete view of the modules for the tableting unit.

Each chapter displays an Estimated Completion Time, enabling learners and managers to plan training schedules effectively. This transparency supports integration into corporate training programs and production planning without disrupting operational activities.

3. Detailed chapter organisation

Within each process training, the modules are typically structured as follows:

• Process Fundamentals – covering scientific principles and formulation basics.

• Equipment Architecture – explaining mechanical design and functional assemblies.

• Critical Process Parameters (CPPs) – detailing parameter influence and interaction.

• Process Optimisation – strategies for maximising efficiency and quality.

• Troubleshooting – systematic problem-solving methodologies.

• Best Practices & Safety – operational excellence and compliance considerations.

This layered structure ensures that learners move from conceptual understanding to applied competence in a logical progression.

4. Interactive learning elements

The Academy is designed to actively engage learners rather than provide passive content consumption. Throughout the modules, interaction is required at multiple points to reinforce learning.

IMA Active Tips are strategically positioned within lessons to provide real-world insights derived from field experience. These tips bridge theoretical explanations with practical application, highlighting common operational pitfalls and best-in-class solutions.

Figure 4: example of an IMA Active Tip in the coating unit.

“Strengthen a Topic” sections appear after critical concepts. These micro-reinforcement modules allow learners to revisit key information before progressing, reducing knowledge gaps and improving retention.

Figure 5: example of interaction points and “strengthen a topic”.

Interactive checkpoints require learners to confirm understanding before unlocking subsequent sections. This ensures engagement and prevents superficial course completion.

Figure 6: example of interaction points and “strengthen a topic”.

5. Case studies and applied learning

A defining feature of the Academy is the integration of realistic Case Studies. These scenarios simulate production challenges such as parameter deviation, product defects, yield variation, or quality and compliance issues.

Trainees are guided through a structured analytical process where they must identify root causes, select corrective actions, and evaluate outcomes. This transforms theoretical knowledge into decision-making competence.

Figure 7: training overview for capsule-filling unit with a focus on case studies.

6. Assessment and final certification

Each process training concludes with a comprehensive Final Quiz.

Figure 8: example of final quiz for coating module.

The assessment evaluates understanding across all mandatory chapters and covers:

• Process theory

• Equipment functionality

• Parameter impact

• Troubleshooting logic

• Operational best practices

Successful completion confirms knowledge acquisition and provides measurable evidence of competence. This supports internal qualification frameworks and global standardisation across manufacturing sites.

Figure 9: example of troubleshooting module in granulation unit.

7. Support for workforce continuity and turnover

One of the most strategic advantages of the Competence Center Academy is its role in mitigating the risks associated with workforce turnover. Pharmaceutical manufacturing relies heavily on accumulated experiential knowledge. When experienced operators leave, organisations risk losing critical expertise.

Figure 10: equipment explained by means of video and dedicated podcast.

By codifying process knowledge into structured digital training, IMA Active ensures that expertise becomes institutional rather than individual. New hires can be onboarded faster, retraining becomes standardised, and operational consistency is preserved.

8. Managerial and organisational benefits

The platform supports managers by offering visibility into training progress, completion status of mandatory modules and certification outcomes. This facilitates compliance with internal quality systems and external regulatory expectations.

Figure 11: training progress evidence on each module.

Training can be integrated into onboarding programs, continuous improvement initiatives and technical upskilling strategies. The Academy thus becomes a long-term competence development partner rather than a one-time training intervention: the platform is updated by IMA experts every year based on innovation in OSD processes.

9. User experience and accessibility

The digital interface of the e-learning platform is designed for clarity, intuitive navigation and modular learning. Learners can progress at their own pace and no mandatory sequencing is requested, just common sense. Content is organised visually to facilitate quick identification of chapters, progress status and interactive components.

This structure enables global accessibility and consistent knowledge dissemination across multiple production sites.

Figure 12: overview of just the central part of granulation process training.

10. Long-term partnership approach

The Competence Center Academy reflects IMA Active’s commitment to customer success beyond equipment supply. By combining advanced machinery with structured competence transfer, IMA Active strengthens long-term partnerships built on shared performance objectives.

Through this initiative, customers gain not only operational efficiency, but a scalable, repeatable framework for sustaining process excellence over time.

Conclusion

The IMA Active Competence Center Academy represents a forward-looking model of industrial education. By integrating structured theory, practical insight, interactive reinforcement, case-based application and validated assessment, the platform elevates training into a strategic capability. In a pharmaceutical environment characterised by increasing complexity and talent mobility, the Academy ensures that critical process knowledge remains protected, accessible and continuously developed.

Figure 13: instructor-led training.

The presence of an expert at the customer facility is always possible to increase the value of the knowledge acquired with e-learning training.

Image Credit: © taweesak - stock.adobe.com