This webinar, presented by Scott Patterson, Vice President, Pharma/BioPharma, delves into advanced solutions for handling powders in upstream biopharmaceutical manufacturing. The discussion highlights common challenges such as minimizing operator exposure, improving powder transfer efficiency, and reducing operational waste in the pharmaceutical and biopharmaceutical sectors. With a focus on innovative ILC Dover technologies like the EZ BioPac™, GMP lift systems, and the JetMixer™, the session provides actionable insights for enhancing safety, productivity, and sustainability in powder handling processes. Explore the full webinar below or read the transcript to gain deeper insights.
Transcript
Introduction
0:00 [Scott Patterson] – Thank you and welcome to our webinar, which is part of the ILC Dover 2021 Virtual Trade Show Experience.
0:07 [Scott Patterson] – I’m Scott Patterson, and I will present a range of solutions for handling powders in upstream biopharmaceutical manufacturing. Let’s get started.
What Problems Are We Solving with the Right Solution?
0:17 [Scott Patterson] – Finding the right solution begins with understanding a day in the life of upstream bioprocessing. We asked processors what they want to fix, avoid, and accomplish.
0:24 [Scott Patterson] – Here are some of the things they told us:
- Reducing powder handling processes altogether was highly desired, as it decreases labor demands and increases manufacturing efficiency.
- Minimizing dust exposure is important for both operator safety and environmental considerations. This also reduces cleaning needs and associated risks.
- Automating the transfer bag handling system is critical to protecting operators from lifting heavy loads, which often exceed safe limits.
- Delivering powder into hydration tanks effectively eliminates issues like pumping and floating, enhancing mixing efficiency.
- Reducing consumables such as cleaning wipes and auxiliary tools minimizes waste, conserves water, and supports sustainable operations.
Why Are There Different Solutions?
1:32 [Scott Patterson] – The diversity in powder handling solutions arises from variations in tank sizes, recipes, and powder characteristics across the biopharmaceutical market.
1:38 [Scott Patterson] – Key considerations include:
- Tanks may differ in size and elevation, requiring adaptable solutions for access and charging.
- Recipes for media and buffer powders vary, necessitating flexible transfer systems.
- Powders themselves pose unique challenges, such as clumping, flow issues, or foaming during hydration.
- Mixing profiles and the transition from durable to single-use systems also influence solution design.
What Can Be Implemented for Better Powder Handling?
2:47 [Scott Patterson] – Today, we’ll discuss three primary technologies for improving powder handling processes:
- Two-Ported 3D EZ BioPac™ Bags: These enable faster, more accurate powder dispensing.
- Drum Charging with Cone Liners: This technique protects equipment and eliminates the need for cleaning components like butterfly valves.
- Jet Mixer™ Technology: A low-shear system that simplifies powder-in-liquid mixing while avoiding foaming.
Two-Ported 3D EZ BioPac™ for Fast and Accurate Dispensing
3:50 [Scott Patterson] – The two-ported EZ BioPac™ offers significant improvements over traditional single-ported, two-dimensional powder bags.
4:45 [Scott Patterson] – In controlled environments like laminar flow hoods, the EZ BioPac™ minimizes space requirements and ergonomics issues while enabling rapid filling. The large open port facilitates adjustments for overfilling and nearly eliminates spillage.
6:07 [Scott Patterson] – Unlike traditional bags that require clamps for sealing, the EZ BioPac™ features factory-folded seals and triclamp connections for a dust-free, secure transfer.
Eliminating Extra Parts that Cause Work and Risk
8:00 [Scott Patterson] – The EZ BioPac™ eliminates the need for separate gaskets, reducing risks of contamination or operator error. The integral co-molded gasket ensures a dust-tight seal, adaptable to a wide range of tank sizes and connection standards.
Powder Hang-Up and Retention in the Transfer
10:14 [Scott Patterson] – Traditional two-dimensional bags can retain significant amounts of powder due to pinch seam welds. In contrast, the EZ BioPac™’s design minimizes retention, eliminating the need for rinse nozzles and associated inefficiencies.
Adding Up the Advantages with EZ BioPac™
11:42 [Scott Patterson] – The EZ BioPac™ reduces cleaning components, minimizes powder retention, and improves safety. A case study comparing 25-liter bags showed the EZ BioPac™ saving approximately 60% in labor time compared to traditional bags.
GMP Lift System to Position Bags at Charge Nozzle
14:12 [Scott Patterson] – Automated lift systems, like those offered by Medo Systems, streamline the transfer of powder bags to elevated tanks. These systems enhance operator safety by reducing manual lifting and facilitating multiple bag connections without repeated trips up and down stairs.
Trolley System to Move Powder Bags Efficiently
15:51 [Scott Patterson] – Non-metallic trolleys offer a cleanable, reusable solution for transporting powder bags through facilities. These systems create a “trolley train,” enabling a single operator to move multiple units efficiently.
Dense Phase Pneumatic Transfer
20:50 [Scott Patterson] – Dense phase pneumatic transfer systems offer a potential solution for moving powders but require extensive cleaning, making them less ideal for biopharmaceutical applications.
ILC Dover JetMixer™
22:30 [Scott Patterson] – The JetMixer™ uses low-shear mixing technology to integrate powders into liquids efficiently, even with poor-flowing or foaming-prone materials. It can also be located remotely, simplifying operations and minimizing contamination risks.
Single-Use Systems for Powder Handling
25:40 [Scott Patterson] – The EZ BioPac™ is designed specifically for powders, with advanced construction methods and materials like ArmorFlex®, ensuring strength, durability, and compliance with biopharmaceutical standards.
Case Study: Implementing the Two-Ported 3D EZ BioPac™
31:42 [Scott Patterson] – A company transitioning from stainless steel bins to the EZ BioPac™ significantly reduced cleaning requirements and capital expenditures. The switch resulted in a more sustainable and efficient powder handling process, demonstrating the flexibility of the EZ BioPac™ for retrofitting existing systems.
Conclusion
Efficient powder handling is a critical component of upstream biopharmaceutical manufacturing, impacting everything from operator safety to production output. The innovative solutions highlighted in this webinar, such as the EZ BioPac™, JetMixer™, and GMP lift systems, offer transformative ways to streamline processes, reduce risks, and enhance overall productivity. By implementing these cutting-edge technologies, manufacturers can achieve greater efficiency, ensure compliance, and foster sustainability.
Ready to elevate your powder handling processes? Dive deeper into the topic by exploring our related blog, “The Right Transfer Solutions for Media & Buffer Powders”, to learn more about how these solutions can revolutionize your operations.
