Case Study: Reduction of Process Batch Time

Project Goal
High market demand and the need for being compliant with United States
regulations required a reduction in the process time in The GansCoater.

Trials were carried out with the goal to reduce batch processing time and save
coating solution.

Details

Machine: GAC 1500

Firm: Pharma Company in Ahmedabad

Product: Drug X, 40 mg

Batch size: 250 kg

The following process parameters were pre-defined:

• Number of spray guns

• Nozzle diameter

• Gun to bed distance

• Spray angle

• Inlet and outlet temperature

• Bed temperature

• Spray rate

• Pan RPM

• Inlet and exhaust CFM

• Atomisation pressure

• Quantity of coating suspension

• Number of nozzles

• Nozzle orifice

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Actual Trial
The spray rate was monitored after loading the batch into the pan. Definite spray
rate was maintained, the pan RPM was monitored closely and at the end, weight
gain was checked.

The following helped decrease process time and the amount of coating
suspension required:

• The initial spray rate was about 200 to 250 g/min, which was increased to
450 to 550 g/min. This contributed to a decrease in process time.

• The gun to bed distance was reduced by 15%.

• The differential pressure inside the pan cabinet was 15-20 mm of water
column, which was reduced to 5-10 mm of water column.

• The cfm of AHU was increased from 3,200 to 4,200.

Results:
• On comprehensive monitoring and experimentation, it was found that the
process time required was 2.5 hours compared to 6.5 hours required
initially, this represents a 61.5% time reduction.

• The time required for batch set up was approximately 30 minutes.

• Tablet coating was satisfactory with targeted tablet weight gain.

• Rejection of less than 1% was attained after inspection.

• Savings of 10 kilograms suspension was achieved.

Conclusion
Following are the positive outcomes obtained because of Gansons services:

• Reduction in batch time by more than 60%.

• Increase in productivity.

• Savings in utilities including electricity and compressed air.

• Improved manpower utilization.

• Savings in coating solution.

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For more information on this case study or any other Gansons products, please
contact:
Samik Sen
Associate Vice President, Marketing
Gansons
+91-9819832901
samik.sen@gansons.com

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