Precision Equipment
Business Unit
Case Studies
The Challenge of Achieving Precise Dosing While Safeguarding Against Exposure
Industry:
Pharmaceutical Manufacturer
Department:
Production Technology Division
Background
The manufacturer showcased in this case study was considering investing in a continuous production facility so that it could increase its generic drug production at a time of increasing cost competition. The manufacturer’s production technology division wanted a solution that could dose consistently while ensuring quality. The system needed to be able to handle future surges in demand while ensuring the safety of operators and complying with good manufacturing practice (GMP).
Problem
Feeder Needed to be Both Safe and Precise and Offer Transparent Controllability
The process of selecting tablet presses and powder mixers for the new production line brought home to the manufacturer the fact that the precision of the loss-in-weight feeder would have a significant effect on product quality. With continuous production came the possibility that the slightest dosing errors could compound to create quality issues.
An employee from the production technology division recalls, “A high-performance system performance means nothing if it can’t dose consistently. Precision was therefore something we could not compromise on.”
So that the quality control division could be briefed and the feeder would be able to handle a variety of materials, clear control principles were an important requirement. The manufacturer also needed to be able to verify in advance that the feeder would consistently dose its own materials: sometimes the properties of the substance being dosed mean that dosing does not go to plan.
In the generics market, it is also impossible to ignore the issue of material loss. A feeder’s ability to dose consistently and precisely affects both quality and cost competitiveness. The manufacturer also envisaged a need to switch temporarily to mass production during pandemics and outbreaks. While the line would not always run at 100% capacity, the manufacturer wanted to be able to switch to continuous production when necessary.
The reduction of exposure risk for workers handling active ingredients was also essential. The feeders had to be safe, including during cleaning.
However, a single feeder that ticked all the boxes of precise dosing, transparent controls, safety, and future-proofing and also had a track record that imbued confidence was elusive.
Summary of the problem
A loss-in-weight feeder’s dosing precision has a direct bearing on quality. The manufacturer couldn’t compromise.
The manufacturer wanted to mitigate risk by testing the feeder with its own materials before committing.
It also needed a solution that incorporated exposure safeguards and could also handle sudden spikes in demand.
