Automated Transferring Unit for Sterile Packaging Assembly
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Solution Overview
Problem
In pharmaceutical and biotechnological industries, manual handling of packaging machine components within sterile environments leads to contamination risks and increased operational costs due to direct operator contact with sterile and potentially hazardous products, necessitating frequent sterilization and operator turnover.
Innovation Solution
A system and method utilizing a transferring unit with a movement arrangement to automatically assemble and dismantle packaging machine elements within a sterile environment, preventing direct operator contact and maintaining sterility, which includes a sterilizing arrangement and a conveying mechanism to move components between a cleanroom and a service room.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling of packaging machine components is performed by operators in sterile environments, then assembly and dismantling operations can be performed, but contamination risks increase and operational costs increase due to frequent operator turnover and protective equipment requirements
Solution Approach 1:
The patent introduces an automated transferring unit as an intermediary device between the operator and the packaging machine components. This robotized system handles the transfer, assembly, and dismantling of components within the sterile environment, eliminating direct manual contact and thus preventing contamination while maintaining operational efficiency
Solution Approach 2:
The patent replaces the manual mechanical handling system with an automated robotic transferring unit. This substitution eliminates the need for operators to wear protective equipment and frequently rotate, thereby maintaining sterility reliability while preserving ease of operation through automated control
2Reliability
If operators wear protective overalls and gloves to prevent contamination, then sterility is maintained, but movement is limited and costs increase
Solution Approach 1:
The automated transferring unit serves as a mediator that performs all operations requiring operator presence in the sterile zone. Operators control the system from outside the sterile environment, eliminating the need for restrictive protective clothing and restoring full mobility while maintaining sterility protection
Solution Approach 2:
The transferring unit is designed to autonomously perform transfer and assembly operations once programmed. The system serves itself by automatically navigating, grasping components, and positioning them correctly, eliminating the need for operators to physically maneuver in restricted protective gear
3Reliability
If frequent operator turnover is implemented to prevent contamination, then sterility is maintained, but productivity decreases and operational complexity increases
Solution Approach 1:
The patent replaces the human operator system with an automated robotic transferring unit that can operate continuously without fatigue or rotation. This substitution maintains contamination prevention while dramatically improving productivity through uninterrupted operation and faster assembly cycles
Solution Approach 2:
The automated transferring unit enables continuous operation without the interruptions required by manual operator rotation. The robot can continuously transfer components, assemble them, and dismantle packaging machines without breaking sterility protocols, thereby maintaining both contamination prevention and high productivity
4Adaptability or versatility
If manual assembly and dismantling operations are performed, then flexibility and adaptability are maintained, but time consumption increases due to sterilization procedures
Solution Approach 1:
The automated transferring unit acts as an intermediary that can be easily reprogrammed to handle different assembly tasks. This digital adaptability replaces manual flexibility while eliminating time-consuming sterilization procedures, as the robot maintains sterility through controlled operation rather than repeated sterilization cycles
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
Enables the automatic handling and transfer of packaging machine components without direct manual intervention, maintaining sterility and reducing operator exposure to hazardous products, thereby minimizing contamination risks and operational costs.
Implementation Method 1
a sterilizing arrangement (4) provided with a first hatch (64) in communication with the inside of said chamber (2) and with a second hatch (65) in communication with the external environment, for sterilising elements (50, 60) to be introduced into said processing chamber (2)
Implementation Method 2
The one-way air flow consists of threads of sterile air that move in the same direction almost parallel to one another, at substantially the same speed, in such a way as to create an even air current without turbulence. The air flow descending from top to bottom forms a front of sterile air that drags away any contaminating particles present and prevents them from rising again from the bottom of the chamber.
Data Source
AI summary
A system for transferring and moving elements removably associable with a packaging machine comprises at least a transferring unit provided with a movement arrangement suitable for receiving and supporting the elements, the movement arrangement being movable for transferring and/or removing the elements to and/or from the machine; a method for transferring and moving elements removably associable with a packaging machine provides supporting and conveying the elements using at least a transferring unit and transferring and/or removing the elements to and/or from the packaging machine using the movement arrangement of the transferring unit.