GEA Pharma Systems Release: Inspired Contained Materials Handling

April 28, 2011 |

5 min read

April, 2011 -- GEA Pharma Systems has built a reputation for matching inspiration with technology when it comes to containment in solid dose processing. But it’s the knowledge and experience to bring that technology together in a creative way to meet customers’ needs that really matters. That is where Buck Systems™ comes in, to integrate materials handling, with granulation and tablet production to form efficient production lines optimised for current needs and sufficiently flexible to be updated as those needs change.

GEA Pharma Systems’ containment technology for solid dose processing falls into three distinct areas and has become trusted technology, especially for applications requiring OEB 4 and OEB 5 (Operator Exposure Band) containment levels:

- The Buck® Valve range that uses the split coupling principle to transfer sensitive or highly toxic powders and granules between IBCs and the processing system; and the Hicoflex? technology, a self-locking coupling that transfers them from flexible sacks into the manufacturing process or vice versa. Together these provide the means to introduce and extract product into the process line at the minimum exposure risk to operators.

- The Collette™ UltimaPro™ range of Single Pot Processors that allow the contained processing of highly potent active ingredients, including mixing, granulation and drying, in a single machine. The Single Pot processors can also be fitted with the Lighthouse Probe™ (LHP) that monitors blend homogeneity, granule formulation (particle size), liquid distribution and drying that avoids the need for sampling and enables full containment to be maintained throughout the process.

- The Courtoy™ MODUL™ tablet presses that provide fast product changeover and high containment using their Exchangeable Compression Modules (ECM). The ECM contains all the components that are in contact with the active ingredient to protect the operator during production. They can be switched in just 30 minutes at product changeover and washed off line (WOL).

Together these three technologies have the ability to create a complete solid dose production facility from the introduction of the active ingredients, through mixing, drying and granulation; and on to highly contained high production tablet production.

R&D flexibility and containment

In addition to the Single Pot approach, described above, GEA Pharma Systems’ range of technologies includes PharmaConnect® and the Contained MP1 Flexstream™ systems. PharmaConnect® is GEA’s innovative, modular granulation, blending and Pelletizing system that allows pharmaceutical formulation scientists to plug in to a range of processing technologies to evaluate processes and optimise product quality. Flexstream™ fluid bed processors allow easy scale up and avoid the need to have special configurations and extra product containers depending on whether the machine is to be used as a dryer, granulator or coater. Together they represent the ultimate in flexible containment technology for R&D and pilot production.

The differentiating factor

But having the technology and knowing how to use it are two different things. The differentiating factor for Buck Systems™ is having the systems integration experience to get the best out of the technology. Phil Gabb, Sales Director and Product Manager for Buck Systems™ explained. “Our engineers work with this technology every day. They really understand what the customers need and how to achieve it using the GEA Pharma Systems equipment. Whatever level of containment is needed or whatever the processing requirements, we can ensure the security of outcome in both product quality and operating conditions to get products to market fast.”

Building design

Intelligent use of technology can also provide savings in building construction, running costs and ergonomics. Buck Systems™ frequently adopts, for example, the sandwich method of building design with the IBCs entering the process on the top floor in a non-GMP environment, being fed via a Buck® valve to the GMP production area on the middle floor, then being discharged into a non-GMP area on the ground floor. This minimises the footprint of the building and keeps all the GMP production in a confined space to reduce the cleaning and HVAC requirements.

Future developments towards ultimate containment

In recent years the developing market for leading solid dose technology has migrated from Europe to Japan, India and South America. This has recently led to Buck Systems™ having its own manufacturing plant and service centres in these countries to provide the local contact, speed of response and on-going relationships with customers, with the support of the UK office providing system design and project management.

But it is in Japan especially where there are now moves to achieve the ultimate containment by removing the workforce completely to create a totally automated system. Buck Systems™ is currently working on a project that uses a conveyor system to move IBCs to and from the GMP area discharging raw materials and recovering finished product all within a secure environment where no operators are present. IBCs are cleaned and stored in a separate area of the plant.

Buck Systems™ is a prime example within GEA Pharma Systems of the company’s strap line ‘Where inspiration meets technology’. Using its experience of the process requirements and knowledge of the technology available Buck Systems™ is uniquely positioned to achieved the desired results, first time, every time.

Buck Systems™ at Interpack

Visit GEA Pharma Systems on stand number F24, Hall 8a and see the complete range of technologies and to discuss systems integration with experienced GEA engineers and sales staff.

Learn more about systems integration at Interpack 2011 www.gea-ps.com/interpack

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Where inspiration meets technology

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Steve Jordan

The Words Workshop Ltd

26 Swanwick Lane, Broughton, Milton Keynes, MK10 9LD

Tel: + 44 1908 695500

Email: steve@thewordsworkshop.co.uk

Web: www.thewordsworkshop.co.uk

All business enquires to:

Phil Gabb - Sales Director