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drum-transfer-system

Drum Transfer System

The essential objectives of containment 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 airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

The fermentation process stimulates enzymatic activity in organic substrates to transform their chemical composition. Fermentation is aided by storying the biomaterials in anaerobic environments, allowing the microorganisms to decompose their nutrient structures. The process is integral to some of the most popular products throughout time such as wine, beer, cheese, and kimchi. But besides the food sector, fermentation is also an important stage in the industrial manufacturing of chemicals, pharmaceuticals, and biofuels.

Fermentation

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.

Batch

Continuous

A high-performance transfer port system that combines ultimate safety, simplicity of operation, and ideal cleaning, used in pharmaceutical and biopharmaceutical manufacturing.
<h2>High-integrity locking system, preventing accidental containment breach</h2>
The Containment Transfer System (CTS) product range from Telstar Life-Sciences is a versatile combination of technologies that provides you with the flexibility to safely and securely transfer products in high containment environments. A number of sizes and design options are available to suit your containment requirements, security needs, and budget.

Contained transfer systems are specially designed as the safest method for transferring product/waste or items in or out of contained or sterile areas. Totally mechanical system (no power needed) with safety devices to prevent incorrect operations (not operator dependent) and with color indicators on the locking mechanism provide visual feedback of the transfer's port status.

Transfer system for high-containment environments

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable 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 systems are used in the food, pharmaceutical, chemical, biomass, and mineral industries to transport bulk powders, granules, and grains for processing and filling.

Conveying

liquid

solid

Testing device of the containment capability of gloves, which is as important as the other parts of the integrated system; and a simple, accessible means of checking interface integrity is critical.


<h2>Testing system to enable fast, easy measurement of glove containment efficiency</h2>
Glove Tester from Telstar Life-Sciences is a low cost manually operated single port testing device designed to allow both in situ and offline testing.

Constructed of acetyl or 316L stainless steel, the device uses air pressure to check glove integrity. It can be designed to suit all types of Telstar ACE glove ports as well as other port brands. The tester inflates the glove at +500Pa pressure for a period of at least five minutes. A leak is indicated by a drop in the pressure reading of the display gauge. An optional colour indicator gives an instant pass/fail assessment.

Glove tester

A crucial step before your products leave the production line is a quality check for dosage and standards. Equipment for measurement and control employs a range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized systems allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing ensures that each batch meets the specified standards. In a continuous process, product testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, and containment, among other parameters.

Testing

Filling of transportation bags and discharging them into mix tanks or reactor vessels is often a source of contamination and there potential exposure of personnel to harmful substances.  Inadequate measures to avoid these issues often slow production and reduce profitability.  Experienced biopharmaceutical manufacturers know that equipment designed for general industry use often falls short and rigid containment and transfer solutions for the biotech industry are often awkward and inefficient. Producers that embrace flexible solutions designed specifically for the challenges of our industry will find an advantage over competitors.


<h2>A fast and clean flexible powder transfer system</h2>
ILC Dover is an industry leader in contained material handling solutions for high-tech manufacturers and end users including NASA. The company's EZ BioPac is a single use solution to contamination free powder transfer for the bioprocessing and pharmaceutical industries.  The system consists of a rigid polypropylene stand with an integrated plastic bag.  The stand holds the bag in an open funnel shape for filling and doubles as a lifting point when the bag is ready to be emptied from the bottom.  The bag is oversized and includes enough material to fold back over the stand during filling to protect the stand from any spillage during filling.  The funnel shape of the supported bag in the filling configuration allows for easy manual addition and subtraction of material to ensure accurate fill weights.  A charge neck at the bottom is clamped to your reactor vessel or fill the tank for discharging and a system of clamps is used to manually control material flow and seal the bag for disposal after it is empty.  Isolation of the contained material is thus maximized, greatly reducing cross-contamination of the powder by substances from the work area, and of the work area by the handled powder.

Flexible contained handling of powder transfer bags

Bagging is the process of packing measured portions of a product into bags that protect it from spoilage, enable easy and safe transportation, and secure the product against tampering and pilferage. The choice of a bagging solution depends on the desired mass or volume per bag, the flow characteristics of the product, and bag construction and design. Bags vary in size from small sachets to bulk flexible containers.

Bagging

Biotech equipment is used for the processing of biological organisms to develop new healthcare-related products. Selecting suitable equipment requires consideration of the process objectives and requirements, the scale of production, and the specific health and safety regulations. Biotech equipment finds applications production of biodegradable plastics, and biofuels as well as in health care.

Bioprocessing

Dosing systems include hoppers, feeders, filling machines, and checkweighers. The selection of suitable dosing equipment depends on the need to dose by quantity, the size of each dose, and the desired dosing rate. The physical form of the material, health and safety requirements and the container to be filled are also important considerations. Dosing systems are used for filling containers in the pharmaceutical industry and for accurate dosing of ingredients in the food and chemical industries. Discuss your dosing challenge with us to receive advice on the most suitable solution for your application.

Dosing

Handling

Transferring powders from drums to process equipment such as reactors or mills can create dusty and hazardous conditions in a manufacturing environment and can be a source of worker exposure to hazardous substances in the pharmaceutical and bioprocess industries. Experienced biopharmaceutical manufacturers know that equipment designed for general industry use often falls short and rigid containment and transfer solutions for the biotech industry are often awkward and inefficient. Producers that embrace flexible solutions designed specifically for the challenges of our industry will find an advantage over competitors.


<h2>Safely and easily empty powder drums without sacrificing containment</h2>
ILC Dover is an industry leader in contained material handling solutions for high-tech manufacturers and end users including NASA. The company's flexible contained drum transfer system allows operators to empty the powdered contents of drums used in the pharmaceutical and bioprocess industries without exposure to the contents. The contents are also protected from potential contamination during the transfer process using this equipment. A flexible containment chamber made from ILC Dover’s rugged Armorflex material is anchored to a raised stainless steel frame using ergonomic bungee cords. The containment chamber includes a discharge sleeve, a drum sleeve, and 2 glove sleeves for operator manipulation of the drum lid and internal liner under contained conditions. A closed drum is placed on the integrated pneumatic drum lift and the drum sleeve is attached. The discharge sleeve is attached to a ring in the frame designed to interface with downstream process equipment. The containment chamber is at a height off the floor which allows the powder to be gravity fed into downstream process equipment or containment solutions placed under it. The operator then raises the drum to the containment chamber with the simple actuation of a lever and opens the lid using the integrated glove sleeves. This manual interaction allows the operator to ensure that all powder flows out of the drum liner to the next process stage without being directly exposed to it. When the drum is empty, its spent liner is placed inside of it and its lid replaced. It is then lowered back to the floor and discarded. The sleeves in the flexible containment system are twisted closed and crimped off ensuring no powder contamination of the surrounding environment. The containment chamber is then discarded and the process repeated for each new drum to be transferred.

Flexible contained drum transfer system

Packaging 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. Choosing the best packaging solution depends on the nature of the product, its end-use, and your production process.

Packing

Tubing frameworks can have rough welding joints, corners and sharp angles that are difficult to clean and maintain. Welded frameworks require time and effort to erect and cannot be easily collapsed for shipping or storage.


<h2>Build tubing frameworks quickly</h2>
ACON from Andocksysteme is a GMP compliant, removable connection for tubing. It can be used to build a tubing framework in all imaginable forms. ACON-connections are water tight and find applications in chemical, pharmaceutical and food industry. The clean, aseptic design is ideal for processing units in clean rooms. ACON connections have no angles, corners, welding joints or visual screws and are therefore easy to clean. Tubing frameworks are easy to assemble with ACON connections and minimize shipping and assembly costs.

Removable GMP compliant connections for tubing

Drawing a sample for evaluation from a running process is not a simple task, especially when dealing with sensitive products. Sampling can break product containment and lead to issues with product quality as well as pose health hazards in the work environment.


<h2><strong>Take samples from a running process without compromising containment</strong></h2>
The ASAM Andocksysteme sampler is the first valve in the pharmaceutical and chemical industry capable of taking a sample from a running process under high containment requirements. The sampler consists of two parts each with one-half of a sphere. The active part of the sampler is firmly attached, with a pad-flange, to the process container from which sample is to be taken. The passive part of the sampler is equipped with a split valve with integrated bore hole and a container for the product sample. The sampler can also be connected to a glove box for evaluation. The containment values achievable are less than 0.01µg/m3.

The contamination-free sampler ASAM can be directly integrated to dryers, agitators, centrifuges, silos, product tubes and other process containers. The halves of the split valves with their specific PTFE seals make SIP and CIP applications possible by means of a special tool.

High containment sampler

Valves fitted in blenders and dryers can have dead spaces that prevent complete processing of the product and negatively affect quality. Ordinary valves can also be difficult to clean and often need dis-assembly for complete cleaning.


<h2><strong>Control product flow with completely opening valves</strong></h2>
Ball valves from Andocksysteme are used in piping, blenders, mixers, dryers, reactors, agitator vessels and sluices to fully allow or completely shut the flow of a product. A segment ball valve consists of a housing and a ball segment supported on both sides by maintenance-free bearings and sealed with an inflatable seal. Andocksysteme ball valves allow even difficult flowing products to pass the valve's unobstructed full bore in a short amount of time. They can be used as both inlet and outlet valve.

Andocksysteme ball valves are also available with CIP nozzles or retractable CIP lances for cleaning without disassembly. They are ideal for dryers and blenders as they have a minimum of dead space which increases product quality. All Andocksysteme ball valves are certified according to air quality control TA-Luft VDI 2440.

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High containment segment ball valve

Transferring active pharmaceutical ingredients from one vessel to another can lead to dust emissions that may be hazardous to the operator. The transfer operation may also expose the product to the environment affecting product quality.


<h2><strong>Control sensitive material flow with high containment</strong></h2>
Split Butterfly Valves (SBV) from Andocksysteme provide a safe method of transferring product from one vessel to another. The valve is designed to minimize dust emission to the operating environment. It is used for the safe transfer of active pharmaceutical ingredients and other products that must be contained for health and safety reasons. These valves also help improve product flow, increase yield and help ensure sterility of the product.

The new SBV docking system consists of an active and a passive valve supported on both sides by high-grade precision bearings. The active valve, operated either manually or automatically, is integrated into the filling or discharging side of the process station. The Passive unit is attached to the mobile container. When docking, the locking pins center the active and passive valve on to each other. Both split valves open simultaneously after docking, discharging the product in a fully contained manner. Andocksysteme SBV's have a PTFE encapsulated sealing system suitable for high containment, chemically aggressive powders and liquids.

High containment split butterfly valve

Thermal and mechanical changes can lead to stresses in industrial piping systems. These stresses can be transferred to components causing misalignment and leakages. They may also cause inaccuracies in weighing and other sensitive measurements.


<h2><strong>Connect chutes and process equipment without pipe stress</strong></h2>
Andocksysteme offers a wide range of compensators and bellows to eliminate misalignment and stress-related issues. These components provide a reliable, stress-free connection between transfer chutes and process equipment with strict weighing requirements. They are ideal for transfer of powders in the pharmaceutical industry. A complete range of injection mold tooling allows Andocksysteme to produce compensators and bellows in the desired length and thickness.

The internal diameter of the compensator is matched to the diameter of the process-chute to eliminate difficult to clean crevices or ledges and allow effective WIP/CIP. Andocksysteme bellows and compensators offer a range of material hardness and connection standards. Material choices include FDA compliant white and black EPDM, Viton, silicone (on request) and FFKM / FFPM elastomers for particularly aggressive duties.

Bellows for pharmaceutical powders

Safe transfer of liquids and hazardous powders into systems can be a challenge in pharma, biopharma and chemical industries. That’s because the slightest possibility of exposure or spillage could cause cross-contamination. Butterfly valves are expensive and clumsy to operate. Technicians require a better solution that is cheaper, faster and easy to operate.
<h2>Disposable Transfer System for Safe Powders and Liquids Transfer</h2>
Ezi-Dock EZI_FLOW™ CSV4 all-plastic valves are a simple, effective solution for transferring liquids and powders in the pharma and biopharma sphere. Their innovative design delivers the ultimate combination of high containment and low cost. They are suitable for reactor charging, extruder charging, powder filling lines and many other applications.

The operator offers up a charge bag containing liquid or powder to the EZI_FLOW™ all-plastic valve. They turn a toggle lever next, to securely attach these parts together. After they have achieved a contained seal they release the charge bag contents through the valve.

Single-use containment valve

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. Advanced technology facilitates the management of tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

Loading powder from a container source to vessels, tanks, or mixers that are under pressure may be hazardous as it tends to explode due to electrostatic charging from collision of the powder particles. Controlling the batch loading of powder particles avoids the risk of explosion and integrating this system into other loading processes can increase safety, hygiene, and production output.


<h2>Loading powders in vessels safely by using both pressure and vacuum</h2>
The PTS powder transfer system from Dec, is a system that uses pressure and vacuum to transfer dry or wet powder and granules from a source to the loading access of vessels, tanks, or reactors. These include very fine powders (&lt;1 micron), wet and cohesive powders (above 50% wetness, as well as low MIE powders (&lt;1 mJ). The system drives the powder into the vessels with no product retention, no particle damage, no segregation, and very low electrostatic charging. It is equipped with a filtration concept using a flat membrane that enables dense phase conveying at a low velocity of 1-3m/s and powder concentrations of 50 to 150 kg powder per kg air. It is also available in an explosion-proof design that can handle 10 bars. The system is hygienic and easy to clean with no need for dismantling.

Powder transfer system

Feeding technology allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding systems are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow.

Feeding

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

The discharge of materials demands strict containment, particularly in the pharmaceutical industry. But big bags, even if sealed, can rip under sustained pressure while in dock position. The risk becomes significantly greater when handling toxic chemicals.
<h2>Big bag discharge docking station for sterile and toxic applications</h2>
Big Bag Discharge Docking System from Dec Group is a pressure-tight system designed for sterile and toxic processing. A wholly-sealed unit, the technology provides containment up to &lt;1 µg/m<sup>3</sup>.

The single dead zone free docking tube is enclosed by an automated cover and ensures a quick operation. An adjustable disposable ring seals the big bag spout, and any remaining liner is easily removed from the side port. The system can be built in various materials and coatings, including stainless steel and HC22.

High containment big bag discharge docking system

Contained transfer systems

Some of the vaccines in use today were originally developed decades ago. But advances in research and vaccine manufacturing equipment provide immunizations from bacterial and viral diseases to more people every year. The Covid-19 pandemic highlights the urgent need to scale up the production of vaccines and ensure a reproducible manufacturing environment.

Vaccines

The word parenteral comes from Greek and means outside the intestine (para=outside and enteron=intestine). In fact, when it comes to parenterals, we are referring to those dosage forms that are administered directly into the bloodstream using a hypodermic needle, avoiding going through the gastrointestinal tract. Using parenteral filling equipment, parenteral solutions are placed in containers such as vials, syringes, or ampoules.

Parenterals

Pharmaceutical cartridges are glass containers of cylindrical shape, suitable for liquid or solid pharmaceutical dosage forms. Generally, these are designed for a specific apparatus such as pre-filled syringes and autoinjectors. Drugs that can be placed in cartridges using a pharmaceutical cartridge filling equipment include insulin, dental anesthesia, and other emergency drugs for allergies.

Pharmaceutical cartridges

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

Active pharmaceutical ingredients (API)

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

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Contained transfer systems

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