Transfer system for powder – Emissions excluded
Especially with highly active substances, the safe transport of active substances and chemicals within an operation is of great importance. The EPTS (emission-free powder transport system) has been designed for the sealed transport of small quantities of solids (powders and granules) under sterile conditions. Many well-known pharmaceutical companies already use the EPTS on a daily basis.
What are the advantages of the emission-free powder transport system?
The system consists of a centrifugal-optimised central container equipped with flap valves on the loading and emptying side as well as a modular set of attachments and sealing parts (tri-clamp). The active substance volume can range from 2 litres to 220 litres, depending on the diameter. Various adapter elements can be mounted on the loading side, such as funnels or adapter parts which can be rendered inert and sterilised. This also applies to the outlet. The high quality of the surface, with an RA < 0.25μm on all process-side surfaces is very important for efficient and optimal emptying. The system is thus adaptable for use with reactors, batch tanks, or tablet presses, for example. The container can be filled and emptied in a protected atmosphere (glove box) or in a vacuum.
How does the EPTS work?
A funnel for filling and/or a CIP chamber for cleaning the entire system can be attached to the valve on the upper part of the container, while the flap valve at the outlet of the EPTS has a connection for the reactor to be filled. When filling, the CIP chamber is completely removed to attach the funnel. The filling funnel is flanged onto the upper part of the EPTS and the medium (powder) is added using a vacuum/suction process. The flap valve is then closed and the CIP chamber is remounted, so that the EPTS can head to the reactor, where it is docked and the powder is added to the process by creating a vacuum in the reactor. If necessary, the trolley can be raised to line up with the reactor. The EPTS clean-in-place system ensures 100% emptying and cleaning of the entire system without emissions. Integrated spray heads and rotating nozzles can be used for CIP cleaning or to ensure optimal emptying of process fluids in a closed system.
The EPTS is optionally available in Hastelloy or Halar coatings. Besides silicon, other seal materials are available, such as EPDM or PTFE (FDA compliant).
The registered utility model of this design has been continuously improved over the years and guarantees high levels of protection for both your products and your employees.
BOLZ INTEC transport and emptying system with unlimited practicality
Minimal residues when emptying reduce risk of contamination
It is always worthwhile questioning established processes, particularly with regard to pharmaceuticals or chemical industry production process. For example, there is the problem of residues left behind when emptying containers. To handle this problem, a funnel with a flap valve is usually placed on the rigging of a stainless-steel drum secured with a tensioning ring and turned over so that the drum can be emptied. However, experience has shown that residual quantities still remain on the funnel neck and on the rigging. This can be attributed to dead spaces in the design which trap residual powdered or viscous media during emptying, wasting valuable products and posing a high risk of both internal and external contamination. In addition to product loss, this also significantly increases the cleaning effort required to meet GMP and FDA regulations. Product residues are therefore a risk in terms of safety and can also hurt the bottom line.
BOLZ INTEC has developed a practical, multi-functional emptying system for drums especially for use in hygiene-sensitive areas which optimises the dead space between the emptying cone and the drum. This ensures that the risk of contamination is kept to a minimum if used and prepared correctly.
The specially designed funnel with a flap in various systems is fixed simply and securely to the drum with a clamping ring and a seal. Users can then use their usual technology for emptying. For an unobstructed product flow, the part of the funnel coming into contact with the product extends into the drum, compared to the contact previously being on the funnel. It is mounted on the drum not unlike a lid thus allowing the drum to be completely emptied. A cap with seal is used during transport and to protect the product.
The drum can be supplied with different bottoms. Tri-clamp connectors can be welded in the version with dished bottom and foot ring. These are suitable for blasting the container with nitrogen during the emptying process (air shock), adding further product components, or using measurement technologies. A CIP lance can also be easily installed either to capture the process liquid for reuse during rinsing or to reuse the drum once emptied. A stirrer can also be used to gently mix the product during emptying to prevent bridging.
Safety comes first
The emptying system can be transported by drum carriage, drum roll, drum lifter, or other transport device. For safety reasons, the emptying system has been reinforced with a footrest and a rail to protect the container when used in unprotected production processes. Correct handling can prevent damage to the drum and the tension closure. Another advantage: since the footrest and the rail are also used as handles, protection, and transport aid, these facilitate the emptying process. The drum seal is tightly welded and very stable to prevent contamination.
The system is available in various sizes with the diameters 315, 375, 400, 450, 500 and 560 mm. The surface is available in bright mill, polished, or electro-polished. The roughness depth is between 0.8 and 1.2 μm by default, but other roughness depths as low as 0.3 μm are also available on request. The transport and emptying system can be delivered in the following materials: 1.4301, 1.4404, 1.4435, 1.4539, or Hastelloy C22 2.4602. The silicone round-snap seals with FDA approval, USP Class 6, and BSE/TSE approval ensure an airtight and secure closure. Sealing materials such as EPDM, VITON are also available.
In this case, the Sole Valve was used to control and steer the flow. This valve permits the continuous feeding of granules and powders without material stoppage, as well as an even dosage during the feeding of processing machines.
Hastelloy drum: the highest-quality drum in the world
Particularly in the pharmaceutical industry, many processes involve liquids and sensitive substances such as enzymes, sera, highly pure, or toxic media. These must often be stored or transported under the most extreme conditions. At the same time, drums require hygienic designs specific to pharmaceutical industry processes.
Use in hygiene-sensitive areas
BOLZ INTEC drums are particularly designed for these hygiene-sensitive areas and resulting ambient conditions. The correct selection of the material as well as smooth and gap-free internal processing of the drums to avoid dead space and cross-contamination as well as 100% traceability are all crucial in order to reduce any risks.
BOLZ INTEC Hastelloy lid drums
These GMP-compliant lidded drums are dull WIG welded with welding filler material and without gaps. The seams are rolled flat, as well as finely polished inside and out. These are also easy to clean and absolutely residue-free and have a high stability even at maximum load. Available according to customer requirements in volumes from 0.5-300 l and in different diameters. The surfaces are polished or electro-polished for optimum product output with roughness < 0.25μm. For simple and airtight sealing, the reusable clamping ring cover with insertable round cord seal as well as sealing materials such as silicone, EPDM, Viton, and the FEP-coated seals with FDA approval.
In addition to the industry-standard materials such as 1.4301 / AISI 304, 1.4404 / AISI 316L, BOLZ INTEC now also offers drums for extreme conditions in 2.4602 / C 22 nickel alloy – HASTELLOY, a material that has been designed and used in the toughest applications, such as in aerospace. Hastelloy C 22 is a very resistant against chloride ions, iodine, and bromine, among other chemicals, even when other high-quality stainless steels suffer corrosion.
Properties of Hastelloy
Hastelloy C 22 is resistant to acids such as sulphuric, phosphorous, or nitric acid as well as chlorine dioxide and is highly corrosion-resistant.
The experience and expertise you need
For the processing of these precious steels, in addition to special approvals, years of experience is necessary, since this resistant material is particularly complex when it comes to grinding and welding. Due to increasing demand for Hastelloy C 22, BOLZ INTEC has decided to put this drum into mass production.
Safe, dust-free and smooth emptying with the drum funnels made of stainless steel straps
When emptying drums, funnels in stainless steel make the whole process dust-free and loss-free. The broad range of BOLZ INTEC funnels runs from asymmetrical and symmetrical funnels to conical drum funnels.
Asymmetrical drum funnels are particularly useful for machines with restricted space, e.g. tablet presses. All products are produced individually or in small batches. BOLZ INTEC is one of the leading manufacturers of asymmetrical funnels. Openings with inside diameters as small as 30 mm can be made from one piece. These can be used with all BOLZ INTEC drums and also with drums from other manufacturers without loss of quality. The angle as well as the surface is freely selectable as bright-milled/2B, polished, or electro-polished. The material thickness is 1.5 mm. 60° and 90° angles in conical funnels is standard, but funnels can also be made according to specific customer requirements. This is where BOLZ INTEC’s expertise and experience pays off. BOLZ INTEC has been making a wide range of filling funnels for years that handle powders with lump breakers and integrated dust extraction, filling funnels with silicone cap, funnel container for storage and ointment filling, as well as different filling funnels for liquid and semi-solid media for renowned pharmaceutical companies.
BOLZ INTEC not only makes one-off pieces or small production runs, but is also very involved in the further development of existing products with regard to profitability, budget, and resource conservation.
Single-use or dedicated application
This is where one of the latest product developments is taken: the BEST COST stainless steel drum for single-use application or as dedicated equipment, taking profitability into account. BOLZ INTEC uses thin-walled stainless steel such as 1.4301, with a diameter of 450 mm and a volume of 100 l or 560 mm and a volume of 200 l, for the BEST-COST drum with a flange.
The BEST-COST stainless steel drum is very high quality, especially with respect to the welding of the thin-walled stainless steels. A low purchase price is offered as well as absolute stability and breaking strength. This drum is about one-third below the price of the standard stainless steel drums. The drum can be used for single-use e.g. for shipping or as dedicated equipment for the storage of ethanol.
The financial and process engineering advantages should not be ignored. Use of BEST COST drums saves resources because the drum is fed into the recycling process directly after use. This eliminates the need for cleaning and at the same time saves a considerable amount of time and money. Applications for patent protection and to transport hazardous goods in the BEST COST drum have been filed.
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BOLZ INTEC stainless steel drums, funnels and containers are especially used in areas with high hygienic requirements such as pharmaceutical or chemical industries. The products are in strict compliance with GMP standards and can also be used in clean rooms. Due to a lean organization BOLZ INTEC can produce and deliver ...