Aseptic Isolator Transfer Stations for Parallel Container Filling
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Solution Overview
Problem
Existing isolator systems for aseptic environments face challenges in throughput rate, design complexity, and handling efficiency, particularly due to the use of gloved hands and single handling devices, which are time-consuming and prone to contamination.
Innovation Solution
Implementing a multi-handling device system within the isolator, including a filling module with multiple stations and transfer stations, allowing parallel processing and simplified handling through the use of transfer stations with receptacles and holding devices that clamp containers transversely for direct insertion and removal in the transfer direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple handling devices are used within the isolator, then throughput rate increases and handling efficiency improves, but device complexity increases
Solution Approach 1:
The system is divided into multiple independent handling devices (first handling device and second handling device) that can operate simultaneously. Each handling device is responsible for specific tasks: the first handling device transfers containers to the filling station and handles filled containers, while the second handling device handles containers at the plug-setting station. This segmentation allows parallel processing and increases throughput rate without requiring a single complex multi-functional device.
Solution Approach 2:
The patent introduces a temporal dimension to the handling process by enabling simultaneous operations at different stations. The first handling device performs operations at the filling station while the second handling device performs operations at the plug-setting station, effectively adding a time dimension to the processing workflow. This allows the system to handle multiple containers in parallel, increasing productivity.
2Ease of operation
If gloved hands are used for manual handling, then contamination risk is present, but handling simplicity is maintained
Solution Approach 1:
The handling devices are designed to automatically perform all handling operations without requiring manual intervention. The devices autonomously transfer containers between stations, position them for filling, and handle them at the plug-setting station. This self-service approach eliminates the need for gloved hands while maintaining operational simplicity through automation.
Solution Approach 2:
The patent replaces the mechanical system of gloved hands with automated handling devices that use robotic or mechanical arms. These devices perform the same handling functions but without human contact, thereby eliminating contamination risk while maintaining ease of operation through automated control systems.
3Productivity
If single handling device is used, then device complexity is reduced, but throughput rate decreases
Solution Approach 1:
The handling function is segmented into multiple independent devices that can operate in parallel. The first handling device manages container transfer to the filling station and post-filling handling, while the second handling device manages operations at the plug-setting station. This segmentation enables simultaneous processing of multiple containers, increasing throughput rate.
Solution Approach 2:
The system ensures continuous useful action by having multiple handling devices operate simultaneously at different stations. While the first handling device is transferring containers to the filling station, the second handling device is simultaneously preparing containers at the plug-setting station. This continuous operation eliminates idle time and maximizes productivity.
Data Source
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AI summary
The invention relates to an isolator system (10) for filling a container (94) with a liquid. The isolator system (10) comprises a filling module (14) with a filling station (38) for filling the container (94) with the liquid, a stopper fitting station (40) for fitting a stopper on the filled container (94), and a plurality of handling devices (42, 44) for handling the container (94) within the filling module (14); a first transfer station (22) for transferring the container (94) to be filled into the filling module (14); a second transfer station (24) for transferring the filled container (94) out of the filling module (14); and a controller (68). The invention additionally relates to a transfer station (130) for transferring a container (94) and to methods (160, 180, 240).