Containment

Reactor and vessel loading systems

The project definition always starts from on-site supervision to check installation area and discuss with end user about specific needs. In function of possible physical constraint first evaluation is about the possibility to use gravity discharge or to evaluate alternative system like Vacuum Transport System (VTS).

First of all, a preliminary design is realized and once the real project starts an ergonomic study on a 1:1 scale mock-up is performed to check real activities to be performed.

Once this critical step is completed the final manufacturing of the system is started.

FPS propose different configurations:

Single chamber mobile reactor loading system for small quantity of product handling, up to OEB4 category (CPT down to 1mg/m3). The system was designed to be movable, flexible and interchangeable on different reactors thanks to adjustable height and transpallet connection system. Product coming in bags (max 8-10 kg each) was safely loaded by FPS bag-in system into main chamber. From main chamber was discharged by gravity or by VTS (Vacuum Transport System) directly into reactor and waste bags removed from back installed FPS Continuous liner system. System rated for ATEX installation area, with full cleaning in place system by integrated spray balls and washing gun. System can be manufactured in AISI316L SS, HC22 or with different surface treatment/coating to meet strict working condition in chemically aggressive atmosphere.
Single chamber reactor charging system for larger quantity of product handling, up to OEB4 category (CPT down to 1mg/m3). The system is provided with FPS integrated drum handling system for safe and easy product charging from drums. The system is especailly designed in fixed or mobile configuration, suitable for gravity discharge or for connection to VTS (Vacuum Transport System). The special design of drum integrated handling system allow the safe use of the system with all available type of drums. Product is charged automatically into main working chamber where an FPS Continuous liner System is installed for safe removal of waste. An FPS Bag-in system is also integrated, so the system is suitable for loading of smaller quantity of product. System rated for ATEX installation area, with full cleaning in place system by integrated spray balls and washing gun. System can be manufactured in AISI316L SS, HC22 or with different surface treatment/coating to meet strict working condition in chemically aggressive atmosphere.
Double chamber reactor charging system for larger quantity of product handling, up to OEB5/OEB6 category (CPT down to 0.1 and 0.01 mg/m3). The double chamber system is provided with FPS integrated drum handling system for safe and easy product charging from drums. The system is especailly designed in fixed or mobile configuration, suitable for gravity discharge or for connection to VTS (Vacuum Transport System). The special design of drum integrated handling system allow the safe use of the system with all available type of drums. Product is charged automatically into side pre-chamber, to increase the overall level of containment of the system. By special pre-chamber design the product (up to 25kg kegs) is moved into main working chamber where an FPS Continuous liner System is installed for safe removal of waste. An FPS Bag-in system could also be integrated, so the system is suitable for loading of smaller quantity of product with CPT down to CPT down to 0.01 mg/m3 . System rated for ATEX installation area, with full cleaning in place system by integrated spray balls and washing gun. System can be manufactured in AISI316L SS, HC22 or with different surface treatment/coating to meet strict working condition in chemically aggressive atmosphere.
Double chamber reactor charging system for larger quantity of product handling, up to OEB5 category (CPT down to 0.1mg/m3). The double chamber system is provided with FPS isolato internally integrated drum handling system for safest product charging from drums. The system is especailly designed in fixed or mobile configuration, suitable for gravity discharge or for connection to VTS (Vacuum Transport System). The special design of drum integrated handling system allow the safe use of the system with all available type of drums, where drums are completely handled into full tight isolator pre-chamber. Drum is positioned and opened inside Isolator pre-chamber, to increase the overall level of containment of the system. By special drum handling and connection system the product (up to 25kg kegs) is moved into main working chamber where an FPS Continuous liner System is installed for safe removal of waste. System rated for ATEX installation area, with full cleaning in place system by integrated spray balls and washing gun. System can be manufactured in AISI316L SS, HC22 or with different surface treatment/coating to meet strict working condition in chemically aggressive atmosphere.

Mock up

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The ability to listen and to adapt to the needs of the customer are the strengths of FPS. The mock-up phase is a unique opportunity for the users and the designers to collaborate.

Is a mock-up really necessary?

Some companies feel that they have surveyed the needs of their internal users well enough that they don’t need to confirm the design with a mock-up and can save some money.

But decades of experience have proven otherwise. Mock-ups are critical to optimize ergonomics, maximize user friendliness (the devil is in the details) and get the end users buy-in (because they are associated to the design process). It also avoids misunderstandings that can lead to small design imperfections which would cost time and money to get solved later in the project.

What is the goal of the mock-up?

A mock-up mimics the final system and help determine the optimal positioning of all the components, simulate the process tasks and the product flow as well as examine the issues that were not discussed previously.

What exactly is a mock-up?

It is a structure that faithfully reproduces the machine on a 1:1 scale and provides a physical representation, as detailed as possible, of what the final system will look like. The structure is typically made of wood. It also allows the designer and the customer to quickly make changes and try different types of improvement during the mock-up review.

Who is involved in the mock-up phase?

It all starts with the ergonomic study from FPS which is carried out by an experienced design team. This results in a General Arrangement Drawing (GA) that is submitted to the customer. The customer project team is typically made of engineers, users and health & safety staff. They review the GA and offer comments. These are integrated in an 3D Design which is the starting point for the mock-up (see below).

What are the steps?

3D Model of the isolator
Drawing the mock-up
Construction of the mock-up
Construction of the internal components (or integrate equipment, tools, containers, etc)
Make the polycarbonate windows and position the glove ports
Mock-up review by the customer and the project team
Final report with the details of the findings and solutions found

What is the mock-up review?

It is a simulation of the routine tasks that the operator will perform inside the isolator. It is preferred that the actual process equipment, tools, containers, etc, are used for this simulation but if not available FPS will simulate them.

The great advantage of making a mock-up is to let real end users perform the tasks and "play" with the system and then critique how these tasks are actually performed with the isolator.

Where is the mock-up review conducted?

Typically, customers visit FPS to perform the review in Italy along with the project manager, the designer and other project team members. For small and medium size isolators, the structure can be shipped to the customer site. It allows the review to take place with the highest number of users and stake holders. In that case some FPS members will visit the customer and a remote session can be organized with the rest of the FPS project team.

Using a mock-up can really help achieve the best possible ergonomics and user friendliness. It fosters strong collaboration between the isolator designers and users. The customer is supported and guided at each step by the FPS project team, that under the coordination of the Project Manager, works together with the customer to find the best design solutions.