Golden designer rules for clean technology

As the trend for production in cleanrooms gathers pace, equipment manufacturers must consider how their technology can be adapted for cleanroom operation.

In the pharmaceutical, biotech and chemical industries, cleanroom technology is becoming essential as processes become increasingly exacting. But this type of technology can be expensive, so every company must ensure that it invests wisely – and wise investment, in this case, inevitably means good design. Westfalia believes that a primary requirement of all cleanrooms is to make them as small as possible. This reduces the running costs and also allows many functions to be performed outside the clean area. But making cleanrooms small is only part of the answer. Cleanrooms must be capable of being maintained without undue interruption of the manufacturing process. They should also be quick to assemble and be capable of being upgraded or modified whenever the applications requires – in other words, be future proof. With pharmaceutical installations all of this equipment requires validating, so there is no room for second chances; everything must be right first time.

Essential components For Westfalia, the key is to locate only those essential components within the cleanroom area, leaving everything else outside and readily accessible. Combining this requirement with other success criteria is all planned carefully – nothing can be left to chance. Firstly, Westfalia uses a modular design for all its components. This allows them to be fully tested in the workshop and significantly reduces the assembly time. More importantly, modular design allows individual components to be manufactured under sterile conditions and validated before assembly to keep the commissioning time to a minimum. Secondly, Westfalia uses 3-D design techniques to ensure that the system will work properly and that all key components are accessible, without using any more space than is absolutely necessary. The Hyperconcentrator (Hycon) from Westfalia is a good example of this modular technology in practice. It is designed with segregated drive parts and process chamber, which are isolated hermetically by a slide ring seal. This two-chamber concept has been achieved by using a suspended bowl and by discharging solids within the cleanroom. It is therefore impossible for the process chamber to be contaminated by the drive technology. To help obtain highly concentrated solids, the bowl is allowed to come to a standstill and the residual liquid removed. Sterile air is used to control the solids discharge process. This can take place at any speed, although low speed is preferable to ensure gentle product treatment. Solids are discharged below the machine under gravity, allowing the system to be adapted individually to meet specific customer requirements.

Avoids contamination This approach completely avoids any contamination or loss of discharged solids as a result of operating liquid and water discharge. The Hycon system uses a hermetic feed that accelerates the product before separation to ensure gentle treatment. It is also a completely closed system, allowing it to be sterilised in place (SIP) by steam.