Drum handling for animal health
Servolift has developed an innovative solution for Boehringer Ingelheim for drum handling that is specifically tailored to the high demands of pharmaceutical production. The project mastered complex challenges in terms of process speed, spatial restrictions, strict GMP requirements, and ensuring maximum operational safety and flexibility.
challenge
1. Extreme process speed and efficiency
The biggest challenge was achieving maximum speed in order to supply the downstream Uhlmann packaging machine without interruption.
- Strict cycle times: Boehringer Ingelheim's specifications defined extremely tight time frames: a complete emptying cycle in just 90 seconds and a return cycle for the empty barrels in 60 seconds.
- Solution: Design of a system that can accommodate two 55-liter barrels simultaneously. This doubles the material throughput per lifting cycle and is key to maintaining the cycle time.
2. Significant spatial and structural limitations
The structural conditions at the installation site posed a considerable technical hurdle.
- Very low room height: The installation had to be carried out in a clean room with a ceiling height of only 3,000 mm. This severely limits the overall height and the mechanical options for a lifting and tilting device.
- Solution: Servolift setzte auf eine kompakte, hydraulische Hubsäule mit einem teleskopischen Tragararm, um die komplexen Hub-, Schwenk- und Kippbewegungen auf engstem Raum zu realisieren.
3. Highest pharmaceutical requirements (GMP and product protection)
Since the system is used in a clean room (“salle blanche”) for the production of veterinary medicines, uncompromising GMP requirements applied.
- Cleaning and sterility: All parts that come into contact with the product had to be easy to dismantle and suitable for cleaning in a GMP washing machine.
- Materials and surfaces: Precise specifications were made: 316L stainless steel for parts that come into contact with the product (surface roughness Ra ≤ 0.8 µm) and 304 stainless steel for external surfaces (Ra ≤ 1.5 µm).
- Dust tightness (containment): The system had to ensure an absolutely tight connection between the barrels and the Y-funnel to prevent any dust emissions.
- Solution: The entire Servolift design follows the principles of “hygienic design”: polished surfaces, no sharp edges, FDA-compliant seals, and a locking system with cones that presses the drums firmly together and seals them.
4. Operational flexibility and uncompromising security
In addition to pure performance, the system also had to prove itself in daily operation and maintenance.
- Ease of maintenance: The downstream Uhlmann machine must be easily accessible for maintenance and cleaning.
- Operating safety: Operation must be intuitive and safe in order to prevent operating errors and hazards for personnel.
- Solution: Servolift integrated two dedicated parking positions. This allows the entire lifting column to be swiveled out of the direct working area of the process machine, which greatly facilitates access for maintenance teams. Safety is ensured by “dead man's control” (movement only when the button is pressed) and a comprehensive system of electrical and mechanical interlocks that prevent dangerous movements.
