Continuous VHP Decontamination Plant for Pharmaceutical Containers
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Solution Overview
Problem
Existing methods for decontaminating the outer surfaces of rigid containers, such as bottles containing pharmaceutical substances, are not suitable for integration into bottle filling and packaging lines due to significant wait times and inefficiencies in the decontamination process.
Innovation Solution
A plant and method utilizing a compensation chamber, decontamination chamber, and aeration chamber with conveyor systems and controlled vaporized hydrogen peroxide (VHP) flows to continuously decontaminate containers, allowing for efficient and continuous processing without interrupting the packaging line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional isolated chamber decontamination cycle is used, then the microbiological load on container surfaces is reduced, but the processing time increases significantly causing wait times for upstream and downstream workstations
Solution Approach 1:
The decontamination process is segmented into three independent chambers (compensation, decontamination, aeration) that operate in sequence. This allows continuous processing where containers move through each stage without interrupting the overall flow, eliminating wait times while maintaining effective microbiological load reduction at each stage.
Solution Approach 2:
The system implements continuous decontamination by having containers constantly move through the compensation, decontamination, and aeration chambers. The conveyor systems ensure that decontamination action is continuous rather than batch-based, eliminating idle wait times for upstream and downstream workstations while maintaining effective microbiological load reduction.
2Loss of time
If the isolated chamber volume is reduced to minimize wait time, then the processing speed increases, but the capacity to handle sufficient container quantities decreases
Solution Approach 1:
The processing line is divided into three separate chambers, each optimized for its specific function. This segmentation allows each chamber to be compact and efficient while the overall system maintains high capacity through continuous flow. The compensation chamber prepares containers, the decontamination chamber treats them, and the aeration chamber finishes the process, enabling high-speed continuous processing without sacrificing capacity.
Solution Approach 2:
The system transitions from batch processing in a single chamber to continuous flow through multiple chambers arranged in sequence. This dimensional change from time-based batch processing to space-based continuous processing allows simultaneous handling of multiple container quantities across different stages, increasing overall productivity while minimizing wait times.
3Reliability
If VHP concentration and humidity are increased to improve decontamination effectiveness, then the microbiological load reduction improves, but the energy consumption and operational complexity increase
Solution Approach 1:
The VHP generation and application process is segmented across three chambers. The compensation chamber prepares the environment, the decontamination chamber applies VHP at optimized concentrations, and the aeration chamber removes excess VHP. This segmentation allows each chamber to operate at optimal energy levels rather than requiring the entire system to maintain high VHP concentrations, reducing overall energy consumption while maintaining decontamination effectiveness.
Solution Approach 2:
Each chamber is optimized with specific local conditions: the compensation chamber prepares containers and environment, the decontamination chamber maintains specific VHP concentration and humidity levels for effective treatment, and the aeration chamber removes excess VHP. This local optimization ensures that energy-intensive VHP generation is concentrated only where needed for decontamination, reducing overall energy consumption while maintaining high decontamination effectiveness.
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 solution enables rapid and efficient decontamination of container surfaces, maintaining VHP concentration and humidity levels, and integrating seamlessly into production lines, improving operational efficiency and reducing microbiological loads effectively.
Implementation Method 1
reducing the microbiological load on the outer surface of closed rigid containers containing a pharmaceutical substance, such as, for example, bottles, tubs, and nests, by using vaporized hydrogen peroxide (VHP)
Data Source
AI summary
A plant to continuously decontaminate containers, comprising: a decontamination chamber having a tray having through openings and a feeding grid to feed at least one row of containers, which are aligned according to a first direction, along the tray, in a second direction, which is transverse to the first direction; a vaporized hydrogen peroxide generator to generate a gaseous mixture comprising air and vaporized hydrogen peroxide; a forced ventilation system to generate, in the chamber, a first flow of gaseous mixture that hits the row of containers from above; and a dispenser system arranged under the tray to generate a second flow of gaseous mixture, which hits the row of containers from below, through the through openings. The feeding grid comprises pushing members uniformly equidistant to each other along the second direction so that any pair of pushing members adjacent to each other can accommodate a row of containers.