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 the flexibility in adapting to the needs of the customer are the strengths that over the years have rewarded FPS.

In FPS the initial study of the project is carried out by several hands: a specialized team works closely with the customer to ensure compliance with the technical specifications required.

FPS usually proposes the construction of a mock-up of the system to be supplied.
It is a structure that faithfully reproduces the machine on a 1:1 scale and provides a visual representation, as detailed as possible, of what the final system will look like. The way in which the mock-up is created allows the designer and the customer to easily make any changes and improvements during the verification stage.

A mock-up is created to outline the aspects and some details that will make up the final machine, in order to establish the optimal positions of all the components, simulate the planned operations and examine any problems that were not discussed in the offer stage.

The steps to consider when making the mock-up are:

3D Design of the isolator
Drawing the mock-up
Creating the insulator mock-up
Creating the internal components
Creating the polycarbonate windows and positioning the glove ports
Checking the mock-up with the customer and the project team
Final report with the details of the findings and solutions found

Before making the mock-up, a careful preliminary study of the machine is carried out, starting from the supply specifications, considering the spaces available at the installation site and the components integrated into the machine (such as process machines or different types of containers to handle). The 3D model of the plant is the starting point for the construction of the mock-up.

In order to achieve the best result, it is necessary to simulate all the operations that the operator will perform inside the isolator; FPS therefore not only simulates the system, but also the main internal components on which the desired operations will be performed.

The customer is supported in each stage by the project team, that under the coordination of the Project Manager, works together with the customer to find the best solutions.

The great advantage of making a mock-up is to let real end users perform the manipulations and "play" with the machine and then define/observe the operations as they will actually be performed.

FPS strongly believes in this sensitive stage because it allows to get a very accurate idea of the machine that will be manufactured, to optimize the ergonomics and logistics for the flow of components and to achieve savings in terms of costs and time on both sides.