CASE
Aseptic powder handling in an isolator – automated and safe
For the aseptic handling of powders cans, we have worked with SKAN to develop a robotic system integrated into a SKAN-isolator. This world first is used by one of the world's leading pharmaceutical company, automatically and safely emptying 12-kilo cans into a mill.
The challenge
Until now, the powder in cans was manually transferred to the isolator and emptied into a mill. This involved first opening the seal, fitting a mechanical valve, then turning the canister upside down and emptying its contents into a mill.
Weighing 12 kilograms per can, this is literally no mean feat. And all this inside a sterile isolator, using integrated gloves - with the added risk of cutting them and kill sterile process.
This complex and delicate process was now to be fully automated. After sterilize the cans for 30 minutes with hydrogen peroxide, the plan was to automatically empty five cans per batch.
The solution
We have developed a high-performance, easy-to-clean plant that complies with GMP and FDA guidelines, all in a compact space. The cans now arrive in the SARA material lock via a roller conveyor, where they are decontaminated for 30 minutes. After decontamination, the first robot removes the canisters from the airlock and places them on the buffer positions in the first isolator.
Like a can opener, it removes the seal from the drum. It then pushes the can onto a cart into the second isolator, where with another robot the cap is removed and placed on its side; the product is now open. Following the robot picks up the can, scans and weighs it.
The can is now emptied into a mill, thanks to a rotary valve integrated into the gripper. Once the can has been completely emptied, the cap is replaced and the can is discharged via an open-rap conveying system.
"Process automation in an isolator is a world first. Thanks to the intelligent engineering of Robotec Solutions and the use of high-quality materials, this has been made possible."
The project
Robot automation in a SKAN isolator is a world first. We developed the system together with SKAN, a pioneering company in the specialist areas of clean room equipment and the construction of isolators for the pharmaceutical industry. The Robotec team included Rolf Kalt (project management, design), Reto Brumann (software programming) and Hans-Peter Meyer (on-site installation, commissioning).
Jörg Lanz, Sales
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