High-Containment in the High Mountains: Chilean Pharmaceutical Manufacturer Uses HPAI Production Plant
Good planning is key
To prevent follow-up deliveries to the country on the other side of the Andes, the system had to be meticulously planned, right down to the smallest details. The following was listed in the introduction to the proposal: first IBC emptying station; second station comprising TW-C20 milling head with Profi-Flex (without drive); third station comprising HW-6 with drive, Profi-Flex and conveyor assembled on mobile lifting column; fourth station comprising conveyor on lifting column for filling drums. Much like in the last section, the most important elements which helped to meet the high demands are listed below.
First station: This is made up of a frame, which can hold IBCs with capacities of 300, 600 and 1,000 l. There is an active valve with a DN200 design at the IBC’s outlet. Below, there is a passive valve with a WIP connection, which can be used to rinse all the places and to wet the parts in contact with the product to effectively prevent product particles from escaping from the system. A fluidisation system with antistatic filter is assembled in the hopper downstream of the passive valve, and there is a dust-free conveyor connection at the outlet. Unlike the three other stations, the first station is not mobile, so it is not positioned on castors, but rather on steel feet which can easily be adjusted to the required height.
Second station comprising TW C20 milling head on our Fredrive platform with Profi-Flex and conveyor, the whole assembled on our mobile lifting column (Fre-Lift). Optimum product homogenisation is performed by the Turbo Witt or, more precisely, the TW-C20, which is made up of a milling head with cylindrical sieve and is connected to the Fredrive drive system.
Third station comprising HW-6 milling head on a second Fredrive platform with Profi-Flex and conveyor assembled on our mobile lifting column (Fre-Lift). The Profi-Valve-150 dosing system with pneumatic drive for continuous product delivery; the feed hopper with fill sensor to prevent the hopper from overflowing; the milling head of the HW-6 hammer mill secured with Tri-Clamps; an outlet hopper with a fluidisation system equipped with an antistatic filter according to the FDA standard; the Fredrive drive system with a freely controllable speed of 1,000 to 6,000 rpm; and the associated PLC with drive control, formula management and alarm diagnostics which is assembled in the control cabinet.
Fourth station: Finally, product filling takes place on the fourth station. The DN200 active valve, a passive valve with WIP connection, a conical outlet hopper and the autonomous Profi-Clean 90 de-dusting system, which cleans the product residue from the interface of the antistatic de-dusting filter, are assembled on the lifting column arm.
The operation of the entire system is controlled by level probes. Each individual process module can be manually adjusted to the correct height on the lifting column and easily connected. Product is transferred with an individually controllable pneumatic conveyor. The entire system is modular and can easily be adjusted to the spatial circumstances and the customer’s process requirements.
Products containing HPAIs are now being processed in Chile, to the customer’s full satisfaction, on what is probably the most flexible containment system that Frewitt has installed to date. Many factors contributed to this result: the customer’s economic situation and Frewitt’s experience in implementing complete solutions.
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