Fast Batch Changes in Hygienically Demanding Processes Using Radar Sensors

Adam Fabriwerk equips the vessels with the necessary components and delivers them essentially

Adam Fabriwerk equips the vessels with the necessary components and delivers them essentially "ready for use" to the pharmaceutical and biopharmaceutical industries.

Thanks to radar sensor VEGAPULS 64, fast batch changes in hygienically demanding processes are now possible

Located in the Indian Nashik, Adam Fabriwerk specializes in producing processing and mixing systems for the cosmetic, pharmaceutical, and biopharmaceutical industries. Among the products which the company manufactures are infusion and injection solutions, antibiotics, and blood plasma products. The materials are directly transferred to the filling stations following production.

VEGAPULS 64 Radar Sensor

Not only does Adam Fabriwerk make the vessels. The company also equips these vessels with the infrastructure they require. This includes magnetic mixers, and buffer and storage containers to CIP modules for lyophilizers, as well as sterilization modules for the biopharmaceutical industry.

The vessels and all other components must comply with the most stringent hygiene requirements, particularly elements which connect to other systems.

Pharmaceutical vessels are rather small compared to those in the chemical industry. Even at Adam Fabriwerk they usually reach a height of only 1.20 m.

Pharmaceutical vessels are rather small compared to those in the chemical industry. Even at Adam Fabriwerk they usually reach a height of only 1.20 m.

Consequently, a sophisticated quality assurance system which meets all FDA requirements is used to monitor each step. The customer-specific control concepts are a significant aspect here, which are used for the widely varying automation levels. The level in the mixing vessel must be monitored continuously and reliably in order to make sure that the process is reliable.

As compared with those in the chemical industry, pharmaceutical vessels are somewhat small. Even at Adam Fabriwerk, they tend only to measure up to a height of 1.20 m. Consequently, when measuring the level, every millimeter counts. In addition, turbulence, magnetic stirrers, high temperatures between 50 and 150 °C, varying vessel bottom geometries, and spray balls during CIP cycles, are also problematic.

Of course, the company was already aware of the advantages offered by radar level measurement technology. After all, the method measures independently of pressure and temperature as well as the liquid’s density, in addition to being extremely accurate.

Ideal for Measurement Down to the Vessel Bottom

Furthermore, it is fast and simple to install the measuring instruments and put them into operation. Particularly given the large agitators, the most important aspect in pharmaceutical applications is that the sensors can measure contactlessly.

Radar sensor VEGAPULS 64 is ideal for measurement down to the vessel bottom.

Radar sensor VEGAPULS 64 is ideal for measurement down to the vessel bottom.

Until now, Adam Fabriwerk got by using differential pressure transmitters in the stirring vessels. However, in their customers' everyday production this often resulted in measurement uncertainties, e.g. when the density of the media changed.

This presented particular challenges to companies in the cosmetics and pharmaceutical industries, as they often alter media in their process vessels, and the vessels require correspondingly regular cleaning cycles. The necessary calibration also represented an impracticality, leading to further inaccurate readings.

A Perfect Solution for Pharmaceutical Manufacturers

The VEGAPULS 64 radar sensor did not need any reconfiguring after it had been installed – not even during CIP cycles. An especially positive effect results from this when the vessels are delivered to the pharmaceutical manufacturers.

Prior to delivery, the sensors can be adapted and adjusted to the vessel. A fully operational system is consequently received by the end customer.

Adam Fabriwerk was enthusiastic about both the new sensor’s simple installation, and the uncomplicated collaboration with VEGA.

Small Containers

This information has been sourced, reviewed and adapted from materials provided by VEGA Grieshaber KG.

For more information on this source, please visit VEGA Grieshaber KG.

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