A leading healthcare manufacturer, specialising in ingestible dietary pills, originally approached us with a need for a Magnetically Driven (Mag Drive) Centrifugal Pump. Drawing on our expertise, we identified a broader process need and transformed the project into a fully integrated, automated system.
Application Details - The Challenge
As part of their production process, the pills undergo a critical cleaning stage using Simulated Gastric Fluid (SGF) prior to miniaturisation. SGF is a chemical solution designed to replicate human gastric acid, typically composed of 3–10% hydrochloric acid along with added salts. The client required a durable, fully automated system capable of handling batch cleaning operations continuously over a seven-day production cycle.
The client previously had no system in place, as they lacked a supplier capable of designing one. Unaware of Tapflo’s capabilities, they then hugely benefited from our Engineering Department’s pump and process knowledge to create a bespoke solution.
The challenge involved creating a fully automated system for their initial test bed and small-scale production plant, ensuring it could follow their trial requirements and provide a working baseline for future production upscaling & development. The system we developed and installed for our client was fully automated, so the production line could run 24/7 without the need to constantly man it.
The IBC Delivery System Solution
As the client faced an issue with no automated system, Tapflo UK’s Engineering Department designed a system that included a duty/standby IBC (intermediate bulk container) SGF delivery system to ensure the constant supply of SGF to the wash facility.
The tanks have multiple wash cycles, of filling and emptying the tanks with SGF to wash the products. Once the wash cycles have been completed, the tanks are emptied into a waste treatment facility, which mixes the SGF with water and a caustic solution to bring the ph down to the required level for the local water board (Thames Water).
The entire system utilises ABS (Acrylonitrile Butadiene Styrene) pipework for chemical compatibility and to ensure simple installation. It also allows for simple modifications for future upgrades. Additionally, to aid with the product’s R&D, an SGF line was also fitted into their facility to dose small quantities.
Components of the IBC Delivery System:
Key Components of the system included:
- Mag Drive Centrifugal Pumps: The pumps are designed to support the SGF delivery and the waste removal process, whilst also providing a chemical cap for fluid PVDF.
- 7x wash tanks: The wash tanks are built from polythene for chemical compatibility. The tanks consisted of filling and emptying them with SGF to wash the products.
- 2x Radar sensors: The IBC Duty / Standby system works based on the level inside the IBCs, which is measured using non-contact radar sensors mounted to the top of the IBCs.
- Electro-Actuated Ball Valves:Â For full control of the system PLC, the Ball Valves are electrically operated; there is no need for a pneumatic supply.
Fully Automated Wash Cycle Using PLC Controller: Fully automated cycles allow the sequence of washers and cycles to run for 24 hours to keep the production line flowing.
- PVDF Float Level Switches for Volume Setting: High level to stop the flow of chemicals
- Automated Dosing of Base for PH Mediation: The acidity was too high for the chemicals our client was draining, so we had automated dosing to correct the level of ph level to drain the chemicals.
- Radar Sensor for Level Control Within Treatment Tank: The non-contact radar sensors are linked to the controller to start/stop pumps.
Benefits of the IBC Delivery System
The implementation of the fully automated duty/standby IBC SGF delivery system achieved these results for the client:
- Fully Automated Wash Sequence: To support the cleaning of the production batches across seven days.
- Fully Automated Waste Treatment: Requires no manual work, so the production line can work 24/7
- IBC Switching: To ensure a constant supply of SGF for the wash facility to cater for overnight & over-weekend working. Allows for an easily accessible source of SGF as required.
Tailored Support from Tapflo UK
The project showcases Tapflo’s UK capability to produce a bespoke system tailored to the Healthcare manufacturing system, not only aligning with operational efficiency but also high standards of hygiene.
If your facility needs tailored support for your operation, don’t hesitate to contact us. Whether that’s a challenging application or a bespoke system, our team have you covered with their years of expertise!