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Maker - Product Challenge

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Changemakers

Powder Containment Equipment

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

Baking powder is perhaps the best-known secret of baking. The leavening agent forms bubbles in dough and batter to give muffins, cakes, and no-yeast pizza their tempting lift. First developed in the 19th century, baking powder production turned baking into the home activity we know today.

Baking powder

Chili powder

This green superfood is known for its remarkable growth rate. It can double its biomass in a matter of hours under optimal conditions. This rapid growth, coupled with its nutrient density, makes it an efficient and sustainable source of nutrition. Sourced from freshwater or sea, washed, and dehydrated, the chlorella powder makes a great addition to your smoothies.

Chlorella powder

Curry powder

The click and puff of inhalers is a universal signal for respiratory conditions. Inhalers quickly grew into preferred drug delivery systems for asthma and COPD. Dry inhaler powder formulation produces a more stable drug than liquid dosage forms. Moreover, inhaler ingredients are more resistant to bacterial growth.

Dry inhaler powder

If you want to make your eyes more attractive and add depth and dimension to them, applying color to your lids is what it takes. Eyeshadow serves this purpose and is available in powder, liquid, pencil and mousse form. In an eyeshadow production line, compact eyeshadows are produced by grinding and mixing powders before compaction, whereas molded eyeshadows are made from waxes and oils mixed with pigments and then poured into molds. Instead, by mixing oils, gelling agents, elastomers, and pigments you can make a mousse eyeshadow.

Eyeshadow

Looking beautiful is hard work. Queen Elizabeth I knows this well. Just think she used so many cosmetics and makeup containing toxic materials, especially lead-based face powder, that she even died from them. Today fortunately, you no longer need lead to make face powder. Simply mix pigments, fillers, dry and wet binders, and compress the mixture using a powder compacting press. Then the face powder is ready to be applied using a powder puff.

Face powder

Flour processing technology has changed drastically since the days of the millstone pulled by a mule. But demand for more refined flour means that the production process is now slower than with more rudimentary techniques. When mixed with water, protein in wheat flour form an elastic gluten structure, giving bakery products their irresistible fluffiness.

Flour

Food powder is the result of drying and pulverizing food. It has been around since the astronauts when out to space. Fruits have a short shelf life and are difficult to preserve due to their high water content.  Fruit powder processing allows you to keep the nutrients of the fruits for a longer time, even off-season.

Fruit powder

In 1682, Denis Papin found a method to remove collagen from animal bones, discovering gelatin. But it was the inventor Peter Cooper who developed gelatin powder processing. In 1845 he secured his invention with US patent 4084 for a dessert of gelatin powder called “portable gelatin”.

Gelatin powder

Any coffee-drinker can agree that a cup of coffee in the morning can brighten up their day. As the most convenient way of making coffee, many people choose to make coffee at home. Whether you want to make Moka coffee or filtered coffee, you need ground coffee that is grind appropriately for the coffee brewing method of your choice. These ground coffee are manufactured by roasting and grinding processes.

Ground coffee

Gypsum is a naturally occurring mineral that serves many purposes, with the United States producing the largest crude gypsum in the world. Cover walls, ceilings, plasters, fertilizers, cosmetics and some foods: gypsum’s vast applications granted it the recognition of "wonder mineral". Gypsum making equipment helps in making gypsum powder or board for industrial use.

Gypsum

Do you know that the famous classical music composer and pianist Ludwig van Beethoven insisted on drinking a cup of coffee made from exactly 60 pieces of coffee beans? Currently, around 50% of the world’s green coffee beans undergo processing through instant coffee manufacturing equipment to produce instant coffee. The process requires roasting, grinding, brewing, and heating to obtain the extract; the coffee extract will either go through a spray drying process or a freeze-drying process.

Instant coffee

Instant soup is quite popular due to its ease of use and quick preparation. Products like cup noodles and vegetable soup mixes are some of the examples commonly used by consumers. The instant soup processing equipment is used to dehydrate or dry components of the soup mixture to prolong shelf life and preserve the taste of the vegetables and other components.

Instant soup

Forged metal objects appear seamless, simple items. But as the use of metals changed over time and constructions became more intricate with additive manufacturing, a new way of processing materials surfaced. Metal powder manufacturing replaces the classic blacksmithing techniques, reducing scrap waste in the meantime. The final metal products, however, retain that shiny allure of the archetypal metal pieces.

Metal powder

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Powder detergent is one of the most widespread washing solutions used in the laundry of fabrics. Since they contain no water, powder detergents are lighter than liquid detergent or pods, which results in cheaper transport and, thus, a more affordable choice for the end consumer. Although manufacturers can formulate their powder detergents differently, the detergent powder production process relies on a combination of builders, surfactants, and enzymes.

Powder detergent

It took the scientific community almost 70 years to agree on the name ‘protein’ and discard the popular alternative, proteid. But protein powder processing still needed another five decades to be commercialized in the 1950s. Once extraction and purification could be industrialized, protein powder soon became a basic staple supplement.

Protein powder

Although popularized recently by NASA this superfood powder made of algae is not a recent discovery. The Aztecs in Mexico and communities around Lake Chad in Africa are known to have harvested and eaten spirulina as a traditional food source. It contains an impressive array of essential nutrients, including complete proteins, vitamins, minerals, such as iron and magnesium, and antioxidants.

Spirulina powder

This powdery food made of dehydrated and ground vegetables is a great way to preserve flavor and nutrition for a long time while still having the benefits of eating fresh vegetables. It is beneficial to turn seasonal vegetables into powders for all-year-round use. Certain vegetable powders, known as green powders, are especially popular as dietary supplements and are used in smoothies for racing a recommended daily intake of vitamins and minerals. Furthermore, vegetable powders can be added to foods as coloring, for instance, in baked goods or to pasta sauces and omelets.

Vegetable powder

andocksysteme-asbv-splitvalve-brochure

Andocksysteme - SplitValve

andocksysteme-asbv-splitvalve-ptfe-brochure

Andocksysteme - SplitValve PTFE

When taking a tablet, it is usually the job of our stomach to break down the medication to make it ready to be absorbed into the bloodstream. However, some drugs are not meant to be dissolved in the stomach because the acidic pH of the stomach can disintegrate the drug, making it no longer effective. Using tablet coating equipment that applies a polymer barrier to the tablet makes it possible to protect it from stomach acidity.

Enteric Coated Tablets

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles for effective drug delivery. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients while optimizing the release profile for immediate release and controlled release.

Multi-layer tablets

Landline telephones in the 1980s were minimalist gadgets that kept getting slimmer in the 1990s. In contrast, cell phones in the same period were bulky and cumbersome. And once they lost their charge, they turned into a giant paperweight. Then came a revolution in batteries and automation with lithium-ion battery manufacturing equipment. Mobile phones packed more power, recharged faster, and endured more recharge cycles. Above all, they were light and small, making cell phones the inseparable companions they are today. But Lithium-ion batteries power much more than phones. As a result, the world is seeing steady growth in battery manufacturing equipment and lithium-ion production lines.

Lithium-ion batteries

The inventor of the lithium-ion battery predicted that solid-state batteries would become commercially available by the mid-2020s, making them an attractive option for energy storage in a wide range of applications, including electric vehicles. This battery type promises a marked improvement in safety, power, and environmental impact compared to current battery packs that use a liquid electrolyte. However, recent breakthroughs in the lab don’t automatically translate into mass production. The complex processing requires specially-designed manufacturing technology to make solid-state batteries a real solution, especially for the automotive industry.

Solid-state batteries

Around a third of your natural protein composition is collagen. But the human body still finds good use for more of it, whether to reinforce joints or aid digestion. Collagen powder processing breaks the chains of amino acids into smaller units, allowing them to be consumed at higher concentrations without changing your diet.

Collagen powder

Manual or automatic operation

Passive valve can be docked in two positions (180° turned)

Easy removal of the insert in contact with the product

Biggest range of valve sizes DN 50 to DN 300

Available in stainless steel 1.4404, optional HC 22 or other materials

Optional add-ons to increase the containment performance

Contained transfer systems are designed to safely transfer the product or waste items in or out of contained or sterile areas. Valves are used to regulate the flow in contained transfer systems. The choice of a suitable containment system depends on the form of source and target containers, the physical state of the product and the volume of the product to be transferred. These systems find applications in transferring pharmaceutical powders from drums to the process equipment, filling bulk chemicals in transportation bags or safely discharging them into mixing tanks.

Contained transfer systems

Chemical

Pharmaceutical

Containment Technology

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

Connect directly with world leading manufacturers of containment technology equipment and find technology to build or improve your production line.

Containment - Making.com

Containment Technology - Making.com

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

Parenteral preparations refer to drugs using non-oral means of administration. Injectables, such as needles and syringes, are used to deliver a drug into the systemic circulation directly in the veins, muscles, under the skin, or in the tissue.

These parenteral formulations are pharmaceutical dosage forms that have strict regulations on being sterile, pyrogen-free, and free from visible particulate matter including reconstituted sterile powders. Solutions, suspensions, emulsions, and gels with APIs intended for administration by injection are usually supplied in vials, ampoules, pre-filled syringes, or pens to facilitate ease of use.

Injectables

Pharmaceutical powders provide longer shelf life and better stability than liquid dosage forms. But the processing of pharmaceutical powders is crucial for growing segments besides pharmacy. Functional foods and cosmetics formulated with active ingredients and excipients depend on powdered forms to fulfill their promises.

Pharmaceutical powder

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Among all dosage forms in use today, tablets constitute the most common one. They are pharmaceutical solid dosage forms containing active ingredients and excipients such as diluents, binders, glidants, and lubricants. Using tablet making equipment, these solid dosage forms are made by compression of granules or powder blends and then shaped by molding.

Tablets

Process

R&amp;D

Safety &amp; Environment

Batch

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

solid

Split Butterfly Valves (SBV) from Andocksysteme provide a safe method of transferring sensitive product like active pharmaceutical ingredients.

Powder containment is the cornerstone of chemical and pharmaceutical manufacturing. Floating particles do not only represent efficiency loss but serious

High containment split butterfly valve - Making.com

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The marketplace for finding innovative production technology

Making.com

brochure_ezi-dock_strap-liner-tie-system-pdf

Brochure_Ezi-Dock_Strap-Liner-Tie-System.pdf

A pre-filled syringe or PFS is a single-dose disposable syringe that is supplied loaded with the substance to be injected. By using a pre-filled syringe filling machine, you can have excellent dosage accuracy due to the exact filling of medications. During administration, safety from potential contaminants is also ensured as they are directly injected after opening. To further minimize the risk of contamination, pre-filled syringes are often filled and sealed in a sterile environment using stainless steel equipment.

Pre-filled Syringes

Double-lock security provides added confidence bags are tightly sealed

Under 1,000th-of-a-milligram / cubic meter leakage assures safety standards

Pneumatic option for fast bag sealing in high production environments

  High containment strength and durability in a variety of operations

Tamper evident systems

Packaging

Pharma and biopharma laboratories need fast effective solutions for tightly sealing bags for isolation and waste disposal. They should insist on

High containment closing system - Making.com

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brochure_ezi-dock_flow_csv-flyer-pdf

Brochure_Ezi-Dock_Flow_CSV-Flyer.pdf

High performance valve for secure liquid and powder transfers

Available in four- and six inch versions for fast, full-bore discharge

  Four- to five-times cheaper than industry-standard butterfly valves

Single use, multi-purpose device ensuring fast, trouble-free supply

Single-use technologies are increasingly being used in the biotech industry due to lower costs, lower risk of cross-contamination, flexibility, and convenience. A single-use bioreactor uses disposable bags instead of a culture vessel to carry out the bioprocess. Using disposable bags, instead of reusable bioreactors, can help reduce the setup time and the time between production cycles. It also reduces sterilization demands for vessel reuse, leading to significant cost savings. In addition to single-use bags, single-use sensors are also employed for efficient and low-cost bioprocessing. Single-use applications are especially suitable for the production of biopharmaceutical products.

Single use systems

Liquid

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

liquid

Safe transfer of liquids and hazardous powders into systems can be a challenge in pharma, biopharma and chemical industries. That’s because the slightest

Single-use containment valve - Making.com

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Everything tastes like porridge, the saying goes. That may be an exaggeration, but in theory, reaction flavors could make everything taste the same. Thankfully, flavorists and chemists in the flavor industry are more inventive than that, and colorful process flavors treat our taste buds to a broad palette of sensations, flavors and aromas.

Reaction flavors

Cost-effective containment system

Safe weighing and dispensing of highly potent APIs

High containment (< 1 μg/m3)

Hazardous area compliance

Provides operator safety

Barrier isolator systems create a physical and an aerodynamic barrier between the operator and the work process. The product or process inside the isolator can only be manipulated through the use of gloves or a robotic arm. Choosing an isolation system involves considering the safety regulations (for example; operator protection or cGMP standards), positive or negative pressure specifications, and monitoring and control requirements. Barrier and isolator systems are used in the pharmaceutical industry for sterile processes such as injectable drug filling and cytotoxic drug compounding. Barrier systems and isolators are integrated into full production lines and the most important thing is to control and monitor airflow.

Containment isolators

Contamination is a major concern in powder handling, not least when processing pharmaceutical products and toxic materials. Highly potent APIs, in

API containment isolator - Making.com

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Suitable for various materials

Provides both product analysis and process optimization

Modular design with flexible, semi-rigid, or rigid wall systems

Product recovery > 99%

Micronizing up to 0.5 μm

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Powder processing for chemical compounds demands product-specific micronizing solutions. Varying material properties and particle characteristics must be

High containment micronizing isolator - Making.com

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The billions of microbes living in our gut have a significant impact on gastrointestinal health, mood, and behavior. Every individual develops their microbiome community. Probiotic processing technology makes sure that harmful bacteria never outnumber good citizens.

Probiotics

The two-piece capsule is a visual shorthand for all types of medical remedies. Advances in technology have made the production of hard-gelatin capsules a convenient delivery method for drugs and other ingested substances. But the simple solution requires micrometric precision to be manufactured to the proper pharmaceutical standards.

Hard gelatin capsules

The nonproprietary name for HPMC – hydroxypropyl methylcellulose – is such a mouthful that it has two abbreviations. Hypromellose is the other one. The non-ionized material offers a safe alternative to gelatin capsules, especially as most common API and excipients are suitable HPMC capsule ingredients.

HPMC capsules

Microtablets range between 1 and 4 millimeters, making the dosage form an excellent delivery system in polypharmacy. The size of the products makes them easier pills to swallow, but microtablets production brings a unique set of complexities.

Microtablets

It is strange how two tablets can belong to the same but at the same time to a different category depending on how the tablet itself is classified. For example, chewable tablets and effervescent tablets have two different routes of administration but both belong to the category of uncoated tablets. Uncoated tablets are prepared by compression of granules in which no coating is added after compression. They may be single-layer or multi-layer tablets.

Uncoated tablets

The fizz of effervescent tablets is commonly associated with a vitamin C boost. But the soluble pill is an excellent drug delivery method for pediatric and geriatric patients. Sometimes referred to as carbon tablets, manufacturing effervescent tablets binds biocarbonate and citric acid that produce the smooth hiss as they dissolve in liquid.

Effervescent tablets

Pre-packaged liners reduce operator error

Continuous liner design increases containment reducing risk of contamination and employee exposure

Interfaces directly with a wide array of existing process equipment

Can also be used with bag in / bag out processes with rigid isolators and flexible enclosures

A flexible containment solution prevents product loss and ensures that personnel is not exposed to harmful substances by locking in the product as it is transferred from one container to another. The choice of a containment system depends on the physical state of the product, the type of container from which the product is being transferred, and the type of container to which it is being moved. Flexible containment solutions are widely used in the pharmaceutical, food, and chemical industries to comply with health and safety regulations.

Flexible containment solutions

A flexible intermediate bulk container is an industrial container designed for the transportation and storage of dry, flowable products in bulk packages. Selection of big bag filling equipment requires consideration of the type of particles to be packaged, type of bag to be used, filling weight/volume per bag, and production volume. Big bag filling equipment is used in the food industry for packaging seeds, spices, salt, and starch. In the pharmaceutical industry it is used for packaging of active ingredients; in the chemical industry for the filling of bulk chemicals, fertilizers, pigments, and plastic granules.

Flexible intermediate bulk containers

Logistics

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Handling

At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with chemicals or hazardous substances since they can be potentially dangerous to human health.

Packing

A disposable drum liner for continuous production of powders.

Powdered products are handled every day in the pharmaceutical and bioprocess industries and an efficient means of filling drums while maintaining

Flexible contained powder discharge into drums - Making.com

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ilc-dover-drum-transfer-system-brochure-pdf

ILC-Dover-drum-transfer-system-brochure.pdf

Ergonomic design featuring bungee cord mounts for the containment chamber and pneumatic drum lift

Integrated glove sleeves allow manual manipulation of drum lid, clamp, and liner without risking exposure

Containment chamber made entirely from clear, flexible, and rugged plastic film known as ArmorFlex

Gravity flow of materials from containment chamber to your equipment or storage vessel

ILC Dover's flexible contained drum transfer system allows operators to empty the powdered contents of drums.

Transferring powders from drums to process equipment such as reactors or mills can create dusty and hazardous conditions in a manufacturing environment

Powder Containment Equipment

Which powder containment technology do you need?

High containment split butterfly valve

High containment closing system

Single-use containment valve

API containment isolator

High containment micronizing isolator

Flexible contained powder discharge into drums

Flexible contained drum transfer system

Crimping system

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