Automated Pharmaceutical Suspension Production Line for Improved Process Control
Project Overview
A major Spanish pharmaceutical manufacturer required an upgrade to their suspension production line to improve manufacturing efficiency, process consistency and automation.
In the precise world of pharmaceutical suspension manufacturing, where processing, cleaning and quality control have to be rigorously adhered to, the company needed a solution that could manage several production steps from pre-mixing and homogenization to final transfer and filling.
The new system also had to integrate with three existing filling machines and the plant’s existing CIP infrastructure, while operating within the requirements of a pharmaceutical clean-room environment.
The Challenge
The existing production system had to be modernized to meet ever-increasing production and process-control requirements.
The main objectives are to:
- Make suspension production more efficient and batch-consistent
- Homogeneous mixing of different formulations
- Decreased mixing and cleaning times
- Integrate the new system into current filling equipment
- Modify existing CIP system to new reactors
- Reduce manual intervention and contamination risk
- Allow for flexible production of different formulations
- Interface new equipment to the existing plant control system
- Keep up good safety and hygiene standards in the manufacture of pharmaceuticals
The INOXPA Solution
INOXPA has designed and implemented a highly automated suspension production line according to the needs of the pharmaceutical manufacturer.
The plant was designed employing state-of-the-art blending technology, automated product transfer, CIP integration and PLC/SCADA-based process control.
The solution was designed to facilitate controlled processing from ingredient pre-mixing through to final filling and allow the manufacturer to cater for varying production requirements with greater flexibility.
Key Equipment & Technologies
4,000-Litre Main Reactor
The main reactor was equipped with multiple agitation systems, including:
- Vertical agitator
- Magnetic tank-bottom agitator
- Heating and cooling jacket
- Product recirculation system
- Multi-tooth high-shear mixer
This configuration supports effective and homogeneous mixing, including the processing of viscous pharmaceutical suspensions.
400-Litre Pre-Mix Reactor
A further 400 Liter reactor was included, used for making ingredient pre-mixes before they are transferred to the main reactor.
It also has specific agitation and tank-bottom mixing to help ensure the even dispersion of ingredients.
Automatic Manifold Filling
After completion, the suspension was transferred to three filling machines and the existing manifold was expanded.
Diaphragm valves and an automatic drainage system guaranty hygienic operation and controlled product transfer.
CIP System Integration
The existing CIP system was modified to clean the new reactors without requiring major changes to the existing infrastructure.
This leads to better cleaning between batches, less downtime and less manual intervention.
PLC & SCADA Automation
The production line is equipped with Siemens S7-1500 PLC and WinCC SCADA system.
This provides centralised programming, monitoring and control of the different stages of production, allowing operators to manage recipes and process parameters more efficiently.
The control panel and associated wiring were installed in accordance with the required safety protocols for the clean-room environment.
Key Benefits
Improved Batch Consistency
Advanced agitation and mixing systems also result in a more homogeneous suspension, which helps guaranty consistent product quality from batch to batch.
Greater Production Efficiency
Automation of mixing, transfer, cleaning and process control minimizes manual intervention and streamlines production operations.
Flexible Manufacturing
The process management through SCADA enables the production system to be modified for different formulations and manufacturing requirements.
Faster & More Efficient Cleaning
Reactor cleaning is done without dismantling and is integrated with the existing CIP system, which helps to reduce the cleaning time and production downtime.
Enhanced Process Safety
Automation and sanitary equipment reduce the amount of manual handling and helps to minimize the risk of contamination during production.
Seamless Integration
The new production line was integrated with the existing filling machines, CIP infrastructure and control environment in the plant, thereby avoiding extensive infrastructure changes.
Supporting Modern Pharmaceutical Manufacturing
This project demonstrates how pharmaceutical manufacturers can improve production efficiency and meet stringent quality and hygiene requirements by integrating process equipment, hygienic design, automation and CIP technology.
INOXPA’s solution offered a scalable and automated platform for suspension manufacturing, enabling consistent production and increased control of the entire process.
INOXPA Pharmaceutical Solutions Through Alantech
Alantech supplies INOXPA processing equipment and solutions for the pharmaceutical industry as well as other industries that require clean processes, precision and automation.
We supply various types of mixing agitators and hygienic processing solutions including CIP solutions as well as others. We can assist you with finding the appropriate INOXPA equipment for your needs.
Planning a Process Improvement for The Pharmaceutical Industry?
If you are planning on building or improving on a pharmaceutical production line or automation process, Alantech will be happy to help you in finding the best INOXPA solution.
For further information about INOXPA pharmaceutical processing equipment and solutions, contact us today!
