IBC System docking station
Wihin an IBC System the transfer of powder and tablets to and from the IBC is often a complex operation and an area in which Buck Systems has become a market leader.
Difficult flowing materials, product segregation, damage and the need to transfer highly potent materials in a high-contained manner are all challenges inherent with charging and discharging IBCs. Buck Systems' unique technology developed by its team of skilled engineers offers practicable highly solutions.
Manual or fully automatic, charging and discharging stations can incorporate a number of different options including vibration for difficult flowing products, air-blast of the valve face and dust extract, and weighing and dosing options for accurate filling and discharging.
Advanced split butterfly valve technology
Buck® and Buck Systems are names which have become synonymous with supplying high containment systems incorporating advanced split butterfly valve technology. Buck Systems' charging and discharging stations use the patented docking system technology available from its sister company Buck® GEA Niro GmbH.
The Buck® Docking System uses two valves:
- The passive valve is the non-driven half located on the outlet and inlet of the IBC, and
- The Active valve facilitates the docking and undocking of the two valve halves and the opening and closing of the valve discs.
With the IBC loaded onto either the discharge or charging station, the passive and the active valves dock. The two external faces of the valves are sealed together to prevent dust contaminating the surfaces. Joint turning allows powder to pass through the valve without the disc faces contacting the product.
Difficult flowing products
The unique patented Vibroflow™ discharges even the most difficult flowing products. Vibration is applied from the discharge station to the discharger located in the container. Powder is prevented from bridging as vibration is applied at the key area where bridging of powder occurs. The product flow maintains a constant speed without hindrance, effectively removing the risk of product segregation.
Accurate dosing system
Proportional control of the butterfly valve, linked into an integrated load cell system, allows highly accurate IBC charging and discharging. Proportional opening and closing pf the valve accurately controls the flow rate of product. The weight of the IBC is fed back to the control system, and as the required weight is reached the system gradually closes the valve to reduce flow of material. Once the required weight has been reached, the valve is closed fully. Buck Systems' dosing systems are of particular benefit during the dispensing stage of the drug manufacturing process, where raw materials need to accurately dosed into IBCs for recipe and batch formulation.
Containment to reduce Operator Exposure Levels (OEL)
Latest designs of discharging and charging stations can further reduce Operator Exposure Levels (OEL) with the addition of the latest Ultra High Containment (UHC) technology.
Product deceleration systems
A range of deceleration systems have been developed by Buck Systems to improve control of solids discharging between processes. These can either be stand-alone devices or an additional feature of the discharge station. The decelerator provides a new technique for feeding products at a controlled low velocity, therefore eliminating segregation of powder or granular materials. Tablet or capsule 'outfeed' systems benefit from reduced breakage, chipping or mechanical damage, resulting in increased production performance and reduced product rejects.
Mechanical and pneumatic decelerators are available. Both exert a 'pinch' at the top of the flexible product chute, preventing the product falling. The 'pinch' is gradually released to allow product to fall at a controlled speed.