Pack off systems

May 5, 2021

Why do people use it?

  • To transfer potent in-process API from a process vessel into drums or bags, through a sieve

What are the issues:

  • Api is highly toxic (OEL 10 µg/m3)
  • Particle size can be uneven: there could be some abnormally large particles

Possible solution (open process):

  • Vibrating screen fixed at the bottom of the process vessel
  • Discharges into a funnel on top of drum
  • Operators wear PPEs
  • Have the operators control the weight

Issues with open process:

  • Cleaning the room will take 1-2 shifts
  • The process is very manual:
    • Very low productivity
    • Risks of human error with the weight
    • Risk of exposure to potent compound
    • Risk of cross contamination (cleaning not 100% effective)

FPS solution (closed process):

  • Process is closed off
    • Cleaning time is reduced by 90%
  • A coarse dosing valve is clamped at the process vessel discharge
    • provides a consistent feed to a vibrating screen
  • In-line vibrating screen which only let the particles with the desired size go through
    • Powder will flow more easily
    • The coarse powder is packed out on a separate packing station, ready to be analyzed and re-processed if needed
  • Fine dosing valve on the desired product line ensures accurate dosing of product
  • Sieved powder is fed into drums through a continuous liner
    • Closed system: no powder floating in the air
    • Safe process for operators: no need for PPEs (better ergonomics and production time reduced)
  • Automatic weighting system controlled by FPS-designed central PLC:
    • High accuracy & repeatability
    • Higher productivity
  • CIP cleaning can use aggressive solvents (system is Explosion-Proof)
  • Retractable spray-balls avoid risk of cross-contamination
  • FDA materials and fully cleanable vibrating screen
  • 1 central control system to operate all the equipment & control the cleaning

Benefits of FPS Solution:

  • No risk of exposure for the operators
  • Process is automated:
    • High productivity
    • 100% accuracy of weighting
  • Automatic CIP system guarantees highly efficient cleaning
    • No risk of cross contamination after product change over
  • Flexibility: powder can be fed to various sizes of drums