Introduction of Flexible Loading Systems
As the supporting
equipment of freeze drying system, flexible loading systems has realized
automatic loading & unloading and transferring of products from freeze
dryer ,which has replaced manual operation, and greatly improve the production
efficiency and meet the sterility requirements.
The flexible loading systems mainly emphasizes automation,
isolation, continuous processing and
systems integration. Integrated with filling machine, lyophilizer and capping
machine, it can complete aseptic transfer of products under the protection of
isolator system. Operators can control and realize the entire automatic loading
and unloading process through HMI.
Composition of Flexible Loading Systems
Flexible loading systems usually consists of three main
systems (sometimes according to the actual workshop layout, the IOS, loading
and unloading systems will be used as both the in-feed station (IS) and the
out-feed station (OS) simultaneously.)
In-feed station (IS)
The in-feed station is responsible for connecting with the
filling machine to ensure enough buffer and continuous operation of the filling
machine. At the same time, it arranges the penicillin bottles in rows to
accumulate the full amount of one layer, acting also as the buffer platform for
the AGV to take materials.
Out-feed station (OS)
The out-feed station is responsible for connecting with
the capping machine to ensure continuous transportation of the capping machine
and acts also a buffer platform for AGV to feed materials.
Automatic guide vehicle (AGV)
Advantages of Flexible Loading Systems
There is no frame for transfer in the production process, automatic loading systemsincreases the effective loading capacity of the plate layer while reducing the risk of human intervention in the frame setting. It can transfer a full layer of materials and achieve high production efficiency, and its loading speed can reach 700VPM and unloading speed 1,200VPM in maximum.
Flexible loading systems can realize the flexible production of multiple lyophilizers according to customers’ demands; a set of system can accommodate to the loading and unloading of multiple lyophilizers, achieving flexible scheduling and being easy to expand production capacity.
Automated and unmanned transfer is completed without manual intervention. Product transfer is always carried out under the protection of unidirectional flow ,which guarantee the repeatability and verifiability of processes.
Aseptic Production Environment
Installed in Class-B filling area, flexible loading
systems can ensure that the products are protected by RABS during the whole
process of loading
The advanced control system processes automatic program operation ,manual as well as emergency operation mode, meeting the requirements of FDA 21CFR, Part11 electronic records, electronic signatures, etc. With user-friendly operation interface and flexible control mode, the control system, based on HMI-PLC double structure design, is equipped with SCADA system, remote control function; its simple and reliable formula management enables fast switching of different production.