Intelligent Fluid Control Technology for a New Formulation Line for Insulin Vials

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Bürkert GmbH & Co. KG

Additional Information

Decentralised Automation Concept — A Ground-Breaking Idea

Decentralized automation is a ground-breaking idea where the intelligence is mounted directly on the valve. The control head integrates features such as the pilot valves for pneumatic control, position feedback and bus communications — all on-board.

In a traditional centralised automation design, this type of information and intelligence is typically located remotely in a control cabinet. Individual runs for both electrical and pneumatic connections are then made to each valve. By contrast, decentralised automation employs a single pneumatic connection and a single bus connection into the field. The ASI gateway is connected to a central PLC and can send the information further onto a SCADA system.

As this intelligence is placed directly in the process environment, it needs to perform in high humidity, high temperature ambient conditions. The Element range has been designed in accordance with EHEDG guidelines, featuring stainless steel and thermoplastic construction, to offer the highest level of chemical resistance. The control head type 8691 has been developed for Bürkert’s Element valve range — however by employing a simple adapter, designed in the company’s Systemhaus, the control head can be installed onto every type of valve used in pharmaceutical plants today.

The Challenge of Flexibility

Another criterion for selecting Bürkert was flexibility, as this project employs a different manufacturer of valves in contact with the insulin. “We also wanted to have the same functions for the visualization and control of these valves. We then proposed to adapt their control head onto these types of valves,” says Gilles. Thus the NNP2 unit was equipped with a total of nearly 370 valves and almost 675 control heads from Bürkert.

Novo Nordisk has not only sought Bürkert valves for their line formulation technologies, but also Bürkert’s conductivity probes — type 8221. “We chose these sensors for their wide measuring range, reliability and repeatability. We use them to monitor the discharge for our CIP fluids and also to control the final rinse lines from our tanks and piping after acid washing”, explains Gilles. In all, there are 44 probes and 15 Multicell type 8619 controllers supplied by Bürkert for the NNP2 unit at Novo Nordisk, specified in close collaboration with Bürkert’s Engineering team.

Through its partnership with Bürkert, Novo Nordisk was able to devise a process solution that improved production yield, whilst simplifying its operability and maintenance. Validation of the installation is scheduled to be completed in September 2013, and production of the first batch of vials of insulin in 2014. Due to this successful collaboration, the pharmaceutical leader is planning to partner with Bürkert for a possible NNP1 unit revamp. “This unit is still based on the old technology. If ever we were to revamp NNP1, I have no doubt that we will try to transfer the benefits of the technologies used on the NNP2 unit,” concludes Olivier Gilles.

* The author is Segment Manager Hygienic, Bürkert Fluid Control Systems, Ingelfingen/Germany.

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