VACUUM CONVEYORS MOVE PHARMACEUTICAL POWDERS WITH EASE

By Brian Wilson, National Product Manager PIAB USA, Inc.

Brian Wilson, National Product Manager for PIAB Vacuum Conveyors,

Vacuum conveying technology has become an indispensable part of the pharmaceutical manufacturing process. It is being used for an increasingly wider array of tasks: moving materials through the drug processing line, blending ingredients in various solutions, even tablet handling. The growing reliance on vacuum conveying is not hard to understand, once you consider its myriad advantages. It is enclosed, hygienic and safe, which is recommended when transferring ingredients and finished products in pharmaceutical processing applications. Powders and granules are ideal for vacuum conveying as well as a number of other materials. Even those materials that are health impairing and/or sensitive to humidity and contamination, can be safely conveyed - without powder leakage into the environment. Most pharmaceutical companies and manufacturers use vacuum conveyors for loading and unloading coating pans. Specifically, some companies are using vacuum conveyors to make and press tablet cores, taking the cores and loading them into the coating pan, where the cores tumble in pots. Then a coating is added until the desired thickness is achieved. Other processors are using conveyors for tablet handling, during processes that involve drilling holes in tablets and shaping them with lasers. Still others make a capsule drug for AIDS, using conveyors to transfer the capsules to the packaging stage of the process. Choosing the best vacuum conveyor for your pharmaceutical manufacturing environment is a challenging task that requires careful consideration. If a system is chosen without the necessary forethought, it may result in serious repercussions, such as loss of productivity, employee hazards, downtime, etc. There are a variety of specific features and benefits to look for when selecting a vacuum conveying system. An ideal system will optimize performance, and increase overall productivity. Look for vacuum conveying systems that offer the following qualities. Pneumatic vacuum vs. mechanical pumps. The most common types of pumps used in vacuum conveying systems are pneumatic and mechanical. The main difference between these two types of pumps lies in their source of power; pneumatic pumps are powered by compressed air and mechanical pumps are powered by electricity. Pneumatic vacuum pumps are smaller, more compact and lighter in weight, which makes them more energy efficient than mechanical Medicine capsules being transported through a vacuum conveyor. pumps. Additionally, pneumatic pumps have no gears or moving parts, which require
Engineer holding a feed wand, used to transport material to a vacuum conveyor. Conveyors are powered by pneumatically driven vacuum pumps and designed to transport up to 15 tons/hour of pharmaceutical powders, such as penicillin, lactose, and potassium.

Vacuum Conveyi ngofPhar maceut i calPowder s

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Vacuum Conveying of Pharmaceutical Powders

Lab testing. This vital step in the conveyor selection process is often overlooked. If you can find a manufacturer with this capability, the advantages are evident. Make sure the lab is able to test-run a variety of powders, granules or fluids, to assess conveying characteristics over various vertical and horizontal distances. You will also want the opportunity to view an analysis of volume conveyed per hour or minute over a given distance, as well as vacuum cycle time and energy consumption. Fluidization. Fluidization allows for compressed air to pass through a porous material, creating a cushion that reduces the coefficient of friction allowing non free flowing material to discharge freely from the vacuum receiver. Fluidization is ideal for the conveying of non-free-flowing powders, a common characteristic of so many sugars and starches. Size/Shape. Ideally, conveyors offer a relatively small footprint, allowing manufacturers to maximize floor space for product production. The shape of various conveyor parts is also an important consideration, not just in terms of efficiency but also as it relates to safety issues. For instance, the conical shape of some conveyor modules makes them stiff and rigid, eliminating the risk of implosion. Durable material. Conveyors for the pharmaceutical industry should to be constructed with a durable material in order to cope with the most demanding circumstances. Easy cleaning ability, combined with the innate strength, makes stainless steel the material of choice for strict hygiene conditions. Although there are more than 60 grades of stainless steel, AISI 316L is chosen for most pharmaceutical applications, because of its superior corrosion resistance and ductility.

PIABs testing facility allows customers to test powder, granule or fluid samples. Testing ensures the vacuum cycle time and energy consumption are effective.

Flow modulation. Users should be able to modulate flow characteristics through the conveyor line by increasing and decreasing the amount of air at the feed point. This can also be achieved by increasing or decreasing the product velocity by adjusting the feed pressure at the vacuum pump. Flow modulation changes the way material is conveyed and provides the operator with greater control. GMP compliance. The pharmaceutical industry is heavily regulated (as consumers would expect): it has to meet all the ordinary legislation on safety, human resources, working practices and environment protection, but it is also required to meet the GMPs (Good Manufacturing Practices). GMP is a set of regulations requiring that quality, safety, and effectiveness be built into foods, drugs, medical devices, and biological products. Its goal is consumer protection, and manufacturers must comply with them, as they carry the force of law. GMP is designed to minimize the risks involved in any pharmaceutical production that cannot be eliminated through testing the final product. Process validation. Validation studies should reinforce GMP (good manufacturing practice) and be conducted in accordance with defined procedures. Process validation ensures that products meet customers expectations every time. FDA requires critical equipment that directly touches the product to be IQ/OQ/PQ validated. IQ validation proves that a particular instrument was installed properly; OQ tests that the instrument meets specifications in the user environment; and PQ tests that the system performs the selected application correctly. Cleaning validation and design qualification (DQ) are other validations that help to ensure that the equipment is in accordance with GMPs. Cleaning validation assures that the product is simple to clean and breakdown, for proper sanitizing or inspecting. Design qualification validates the documentation of user requirements and instrument functional and operational specifications. The ease with which the system can be validated is an important consideration in the purchase of the system.

Vacuum Conveying of Pharmaceutical Powders

Access to accessories. Customers should look for a vendor that can provide a selection of accessories for the conveying system, such as feed wands, feed adapters and portable stands. Devices such as these can greatly optimize the conveyors performance. Warranties. Like any industrial product, conveyors come with warranties that protect the user against costly repair during the warranty period. Some conveyor manufacturers offer warranty periods of up to five years. Employee safety. Having your employees manually scoop pharmaceutical ingredients can put them at risk of breathing toxic chemicals into their lungs. Additionally, lifting and handling of heavy sacks can result in serious back or shoulder strain. With the proper conveying system, a greater number of materials, even those that are health impairing and/or sensitive to humidity and contamination can be safely conveyed, reducing the risks of employee inhalation or physical injury. Environmentally- friendly. With the increasing need for energy efficiency and low contamination, the government has been tightening regulations on emission control. Make sure your conveying equipment complies with the latest pharmaceutical industry standards; mechanical systems often pose a threat of oil or lubricant contamination. Clearly, a conveying system is not an impulse buy. It requires careful consideration of numerous criteria regarding performance, safety, ergonomics, and flexibility. But the time spent in this process will be an invaluable investment in the overall health of your pharmaceutical manufacturing operation.
The fluidization feature creates a consistent, reliable flow of product both in the feed source and the discharge from the vacuum receiver. Fluidization is ideal for the conveying of non-free flowing pharmaceutical powders.