Barrel Mixers in Use for Animal Health
Servolift has developed an innovative drum blender with a through-the-wall design and an integrated lifting function for our client ELANCO. The system ensures the safe handling, mixing, and emptying of drums with volumes ranging from 70 to 400 liters. As a full-service partner, we supported the entire project—from delivery and the Factory Acceptance Test (FAT) through installation and commissioning to the final handover, including comprehensive operator training.
The Challenge in the Project
GMP/Cleanroom Requirements: Smooth surfaces, sealed joints, easy cleaning.
Process Integration: OPC UA interface, connection to MES, 21 CFR Part 11 compliance, and audit trail functions.
Safe handling: five different drum sizes, reduced human intervention, protection of the hazardous area via an immaterial protective field.
Space and installation restrictions: through-the-wall installation with separation of the process and technical areas.
How the Customer's Requirement Was Met
Mechanical Components: Delivery of a lifting column with an integrated mixing drive, motorized V-jaw clamping, and a tilting mechanism (30°), mechanical stops, and a double safety chain.
Safety: Safety light curtain, laser height measurement, pilot check valve on the cylinder, and pressure limiting for overload protection.
Automation: Siemens S7-1500 PLC, 15" HMI, recipe management, batch reporting, OPC UA (read-only) for MES, UPS for controlled shutdown.
Documentation & Qualification: FS/FDS, IQ/OQ, SDS, HDS, FAT protocols, and operator training provided by Servolift.
The Benefit for the Customer (ELANCO)
Operational Safety: Reduced risk to personnel and product through automated processes and multiple safety barriers.
GMP Compliance & Traceability: Formula management, batch reports, and audit trails improve compliance and batch documentation.
Efficiency gains: Faster, reproducible mixing cycles (5–20 rpm), less manual handling, simplified discharge into containers or grinders.
Seamless IT integration: Read-only OPC UA access for MES reporting; central user management via Active Directory is possible.
Perfect mixing results with full drums (100% fill level) The volume expansion ensures a homogeneous mixture, even when the main tank is completely full of product. The principle is simple but effective:
In this process, an extension vessel (with approximately one-third of the base volume) is tightly connected to the primary drum—which is completely filled with product—using a Tri-Clamp connection. This configuration creates the headspace required for the process during the subsequent tilting and rotation operation. The space created in this way allows the powder or granule bed to cascade unimpeded, ensuring a reproducible and homogeneous mixture of solids.
