Drying Oven CIP System for Coating Line Cleaning
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Solution Overview
Problem
The existing manufacturing processes for multi-layer composites face challenges in achieving rapid, thorough, and economical cleaning of the drying oven in coating plants, which is crucial for preventing cross-contamination and minimizing downtime, especially when producing transdermal systems or wafers, where precise humidity control in multiple drying zones is necessary for product quality.
Innovation Solution
The implementation of a CIP system integrated into the drying oven with independent air flow regulation in each zone, combined with a heating-nozzle system for uniform air distribution and easy access for cleaning, ensures thorough and efficient cleaning without dismantling components, using hollow shaft rollers with spray nozzles for internal cleaning and a conical design for liquid collection and disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drying oven is cleaned by dismantling components, then cleaning thoroughness is improved, but production downtime increases and operational complexity increases
Solution Approach 1:
The drying oven is equipped with an integrated CIP (cleaning-in-place) system that enables the oven to clean itself without dismantling components. The system includes spray nozzles positioned to deliver cleaning solutions to all internal surfaces, pumps for circulating cleaning fluids, and drainage systems, allowing thorough cleaning while the oven remains assembled and operational capacity is maintained.
Solution Approach 2:
The CIP system utilizes hydraulic principles by circulating cleaning solutions through the drying oven using pumps and spray nozzles. High-pressure cleaning fluids are delivered to all internal surfaces including corners and niches, and used cleaning solutions are drained away, achieving thorough cleaning through fluid dynamics without mechanical dismantling.
2Productivity
If the drying oven is cleaned quickly, then production downtime is reduced, but cleaning thoroughness may be compromised
Solution Approach 1:
The drying oven interior is divided into multiple spray zones with dedicated nozzles for different sections including corners and niches. This segmentation allows simultaneous cleaning of all areas through coordinated spray patterns, achieving thorough cleaning of the entire volume without requiring sequential manual cleaning of each section, thus maintaining both speed and thoroughness.
Solution Approach 2:
The CIP system is designed to handle multiple cleaning functions through a single integrated system: spraying cleaning solutions, circulating fluids, draining waste, and controlling temperature. This multi-functional approach consolidates what would otherwise require multiple separate cleaning operations into one unified process, achieving comprehensive cleaning efficiently.
3Reliability
If cross-contamination is prevented through thorough cleaning, then product quality is improved, but cleaning time and resource consumption increase
Solution Approach 1:
The integrated CIP system enables automated self-cleaning of the drying oven, eliminating the need for manual disassembly and cleaning operations. The system circulates cleaning solutions through all internal surfaces, including corners and niches, ensuring complete removal of contaminants that could cause cross-contamination, while maintaining production schedules through rapid cleaning cycles.
Solution Approach 2:
The CIP system incorporates feedback mechanisms through sensors that monitor cleaning solution circulation, spray activation, and drainage efficiency. This feedback ensures that cleaning operations are completed thoroughly and consistently, verifying that cross-contamination prevention requirements are met while optimizing cleaning cycle timing to minimize production downtime.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables quick, validated cleaning of the drying oven, maintaining humidity stability across zones, preventing cross-contamination, and reducing downtime, ensuring the system's readiness for new production runs while ensuring product quality and compliance with GMP standards.
Implementation Method 1
at least one guide roller is equipped with at least one cleaning nozzle, through which liquid and/or gaseous cleaning substances can be guided into the treatment section
Implementation Method 2
The drying oven can include one or more drying zones. The individual drying zones are distinguished by their different temperatures and air volumes
Implementation Method 3
the moisture from the coated multi-layer composite gets into the air flow
Implementation Method 4
the cleaning liquid speed flows together in the lower housing part of the drying oven, which tapers conically downwards, and is discharged there via a drain
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method of production for a mono- or multilayer compound, comprising several steps, wherein first one or several layers are applied onto a carrier material by coating with a liquid component, the multilayer compound is then dried and the dried mono- or multilayer compound is then rolled up, wherein, in a final step, the installation is cleaned. During the drying of the coated multilayer compound, the air circuit in the drying oven (5) is entirely set to fresh air supply, and the inner chamber of the drying oven is configured to be cleaned in a controlled manner. As a result, all components of the drying oven (5), which can come into contact with the product produced therein, do not have to be removed for the purpose of a GMP-compliant cleaning, but can be cleaned with the aid of the system using CIP technology which is integrated into the drying oven (5). Furthermore, the outer housing of the drying oven is designed in such a manner that the upper part (11) of the drying oven (5) can be lifted off in the upward direction, and all assembly parts in the interior of the drying oven are designed such that a dismounting for cleaning purposes is not required. All transport rollers (17), by means of which the coated mono- or multilayer compound (14) is moved through the drying oven (5) and the individual drying zones (T1 to Tx), are designed as hollow shafts and provided with spraying nozzles.