IBC, Blending, and Powder Handling Technology

More and more pharmaceutical manufacturers are operating with discrete batches using intermediate bulk containers (IBCs) for handling, storage, and tumble blending. IBCs may be custom-designed to suit each customer's specific needs, in a wide range of sizes, with charging and discharging valves in a variety of sizes and styles. IBCs are designed for handling by manual or motorized pallet trucks, forklift trucks, or automatic guided vehicles (AGVs), and often a combination of features to provide the maximum flexibility of movement and handling.

In-Container Blending

A major advantage with the use of IBC systems is the ability to carry out in-container blending and homogenizing of dry powder formulations. Tumble blenders may be designed to interface with IBCs of all sizes. The IBCs may be placed into the tumbling machines using hand pallet truck, fork truck, AGV, or conveyor. Stainless steel products meet cGMP requirements. Machines are normally controlled by plcs using specialized software that stores blend recipes and record blend data electronically or via a paper roll printer.

Washing

An important feature of any IBC system is the ability to wash the containers to a consistent, repeatable standard, both internally and externally. Wash stations may be single entry or pass through, loaded by pallet truck, AGV, or conveyor. They can be manually operated or fully automated with plc control of a selection of wash cycles. Metering controls the addition of detergents or sanitizing fluid to the system, and systems may also add purified or municipal water. A standalone service module supplies air drying and cooling, as well as housing a heat exchanger, valves, pumps, and detergent tanks. Depending on throughput demands, systems may use single or multiple units.

Charging & Discharging

Charging may be accomplished with a variety of machines. A patented seal arrangement is used to contain powder during the charging process. Where high containment is required, a patented split disc valve ensures that emissions comply with all standards. The system may be fully automated for operatorless control. Additional features include air-blast cleaning of IBC valves, secondary covers over charging chutes, and weighing to detect fill status.

Through-the-Floor Discharging

Properly designed systems achieve dust-free product transfer from container to downstream equipment. For multilevel plants, through-the-floor systems can use manual, semi-automatic, or fully automatic discharging. Secondary covers and valves are opened and closed automatically by a plc processor. It can also control air-blast cleaning and extraction to ensure that traces of product are removed from the IBC valve when it departs the discharger.

Solids Deceleration

Specialized solids deceleration devices have been developed for improved control of solids discharging. Theses devices exhibit positive control of solids feed rate for a smooth, dust-free transfer. They are available for drop distances of 1.5 to 3.5 meters, and use a fully automatic interlocked control system. An optional proportional controller for the pinch roll opening allows variation of discharge rates.

Technical article about blending with NIR (pdf)