Pharmaceutical Powder Processing System with Cleaning Tunnel
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Solution Overview
Problem
Current processing systems for pharmaceutical powders are costly, inflexible, and require high operational effort due to the need for extensive protective measures and rigorous cleaning procedures, which restrict operator access and increase the risk of contamination and equipment malfunctions.
Innovation Solution
A processing system divided into zones with varying levels of contamination, utilizing a cleaning tunnel with a suction device and pressure differences to contain and remove contaminants, allowing for reduced protective measures and easier access during operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a closed housing with tight sealing is used to contain powder residues, then operator protection and environmental safety are improved, but device complexity and cost increase significantly
Solution Approach 1:
The processing device is divided into multiple processing stations arranged in a sequence, with each station capable of being independently accessed. This segmentation allows operators to access specific stations without needing to open a completely sealed housing, thereby reducing the sealing requirements while maintaining protection against powder residues.
Solution Approach 2:
A cleaning gas flow is introduced as an intermediary substance to remove powder residues from processing stations. The cleaning gas flows through the processing stations, dissolving and carrying away powder residues, thereby eliminating the need for intensive water rinsing and reducing the complexity of sealing requirements.
2Object-generated harmful factors
If intensive water rinsing and cleaning procedures are implemented, then contamination is reduced, but loss of time and operational efficiency decrease
Solution Approach 1:
The mechanical water rinsing process is replaced by a gas-based cleaning system. A cleaning gas flow is generated that chemically and physically removes powder residues without requiring water. This substitution eliminates the time-consuming water rinsing steps while maintaining effective contamination removal.
Solution Approach 2:
The cleaning medium is changed from liquid (water) to gas (cleaning gas). This parameter change allows for more efficient and faster cleaning, as the gas can penetrate and remove powder residues without the limitations of liquid rinsing, thereby reducing cleaning time while maintaining effectiveness.
3Device complexity
If standard machines are used without specialized closed housings, then device complexity and cost are reduced, but reliability of contamination control deteriorates
Solution Approach 1:
The processing device is designed to perform multiple functions: it processes powder materials while simultaneously maintaining contamination control through integrated cleaning gas flow systems. This multi-functionality allows standard machine structures to be used without requiring specialized closed housings, as the cleaning gas flow provides the necessary contamination control.
Solution Approach 2:
The cleaning gas flow serves as an intermediary that provides contamination control without requiring a sealed housing. The gas flows through the processing stations, removing powder residues and preventing contamination, thereby enabling the use of simpler, non-sealed housing structures while maintaining reliability.
4Object-affected harmful factors
If access to processing stations is restricted for operator safety, then operator protection is improved, but ease of operation and troubleshooting difficulty worsen
Solution Approach 1:
The processing device is divided into multiple processing stations that can be accessed independently. Operators can access specific stations for troubleshooting or maintenance without exposing themselves to contamination from other stations, as the cleaning gas flow system provides localized protection. This segmentation improves both safety and ease of operation.
Solution Approach 2:
The cleaning gas flow acts as an intermediary protective barrier that allows operators to access processing stations safely. The gas flow continues to remove powder residues even when stations are accessible, thereby maintaining operator safety while enabling easy access for troubleshooting and maintenance activities.
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
The system effectively contains contaminants within specific zones, reducing the need for intensive cleaning and allowing for easy operator access without special protective measures, enhancing flexibility and reducing operational costs.
Implementation Method 1
A suction device (6) is arranged in the region of an opposite second end (46) of the cleaning tunnel (44), by means of which a cleaning gas flow (56) is generated in the cleaning tunnel (44) during operation
Implementation Method 2
first means (54) for generating a first pressure difference between the second zone (II) and the first zone (I) are provided, with these means being designed and used during operation in such a way that an internal pressure (p2) prevails in the housing (52) of the second zone (II), which is lower than a pressure (p1) in the first zone (I)
Data Source
Figure 1~2
AI summary
A processing system (1) and a method for processing, in particular, pharmaceutical powders. The processing device (5) comprises several processing stations (41, 42) that are used cyclically. The processing system (1) has at least one first zone (I) and a second zone (II), with each zone (I, II) having at least one processing station (41, 42) of the processing device (5). A cleaning tunnel (44) is arranged in the second zone (II), which extends over at least one processing station (42) of the second zone (II). A first end (45) of the cleaning tunnel (44) adjoins the first zone (I). An extraction device (6) is arranged in the region of an opposite second end (46) of the cleaning tunnel (44). A cleaning gas stream (56) is generated in the cleaning tunnel (44) by means of the extraction device (6).