Laboratory Filtration, Washing and Drying Machine (100L Flat Plate Three-in-One)

The problems existing in the traditional pilot-scale process of active pharmaceutical ingredient filtration, washing and drying include poor washing effect of filter cakes, high labor intensity of manual operation, difficulty in material transfer, easy influence and contamination of materials by equipment transmission components and open environments, and difficulty in operation and verification of equipment cleaning and sterilization, etc. These serious defects have a significant impact on the color grade, contamination and visible foreign matter quality indicators of the drugs.

Wuxi Sunray has integrated the traditional pilot-scale process for the crystallization and drying of active pharmaceutical ingredients, making breakthroughs on the basis of inheriting the essence of tradition. Starting from equipment reform, integrate its processes to form a new pilot-scale process equipment scheme for the crystallization and drying of active pharmaceutical ingredients. Starting from simplifying the process, the filtration, washing and drying processes are combined on one machine to complete, reducing the number of process transfers. Starting from automation, washability and sterilization, improvements should be made to make the overall process more suitable for the production of sterile active pharmaceutical ingredients.

Technical Instructions for Laboratory Filtration, Washing and Drying Machine

(1) The laboratory filtration, washing and drying machine continuously operates the entire process of filtration, washing and drying within the same equipment, automatically discharges materials, avoids contamination, and meets the requirements of the pharmaceutical production process.

(2) The equipment consists of a tank, a stirring system, a filtration system, a heating and insulation system, and a control system, etc. The equipment is safe, stable and reliable.

(3) The equipment tank adopts a split structure with a detachable chassis, which is connected to the tank through a hydraulic quick-opening mechanism.

(4) The tank wall is equipped with a heating jacket to indirectly heat and dry the materials through heat conduction.

(5) An insulation layer is set on the outer surface of the equipment for heat insulation and to reduce heat loss.

(6) The stirring system is equipped with an S-type internal heating double-blade hollow stirrer, which can thoroughly stir and heat the filter cake, improving the efficiency of washing and drying.

(7) The chassis filter adopts 6 layers of 316L stainless steel sintered mesh.

(8) Through hydraulic transmission, the lifting of the chassis, the hydraulic locking of the chassis, the lifting of the stirring blades, and the discharge switch are achieved.

(9) Set up a main shaft bellows integrity detection system;

(10) Set up a vacuum sampling device. The qualification of the material can be determined after sampling at the sampling port. Sampling can be operated under vacuum conditions, so that the vacuum degree inside the conical cylinder will not be affected throughout the sampling process and the drying process will not be interfered with.

(11) The CIP online cleaning system adopts a design with multiple spray heads, which facilitates the online cleaning of the main unit and auxiliary pipelines, meeting GMP production requirements. The structural design and processing technology of the accessories and connecting pipelines of the CIP online cleaning system must ensure no dead corners, easy cleaning and easy disassembly and assembly.

(12) The mechanical seal and the part of the tank that comes into contact with the material are internally in-situ cleaned by rotating the cleaning ball. The outer sealing liquid cavity of the mechanical seal and both sides of the wear collection cup are equipped with cleaning ports.

(13) The dust vacuum filter is directly connected to the dryer cylinder, allowing for quick replacement of the filter element. It also meets the online cleaning requirements and complies with GMP standards. The pressure transmitter installed on the filter is connected to the automatic control system. Before the filter screen gets clogged, it automatically blows nitrogen back to prevent clogging, ensuring the unobstructed flow of the vacuum pumping pipeline.

(14) The side discharge valve is equipped with an air sweep device with multiple air blowing ports. When the discharge port is closed, external power can blow external air into the air blowing holes to sweep the material residues on the valve plug and the base of the discharge valve, meeting the clean production requirements of GMP and FDA.

(15) The automated temperature control system uses Pt100 platinum resistance as the detection element for temperature detection, which is directly inserted into the cylinder to reflect the vacuum temperature of the material. The temperature detection signal controls the opening and closing of the heat source entering the valve through the temperature regulator to meet the optimal temperature required by the material.

(16) The pressure transmitter adopts PLC control. The strict and effective control system not only ensures the automatic operation of the equipment but also greatly improves the reliability of the equipment operation, thereby effectively guaranteeing the quality of the products.

(17) The control system adopts Siemens PLC and on-site LOP operation. It features a compact human-machine interface, simple operation, convenient maintenance, expandable output, and provides space for equipment upgrades.

Technical parameters of laboratory filtration, washing and drying machine

(1) Equipment model: BXG-DN600

(2) Tank design pressure: -0.1 to 0.35MPa

(3) Working pressure of the tank: -0.1 to 0.3MPa

(4) Tank design temperature: ≤100℃

(5) Working temperature of the tank: -20 to 80℃

(6) Coil design pressure: -0.1 to 0.45Mpa

(7) Coil working pressure: -0.1 to 0.4Mpa

(8) Coil design temperature: ≤110℃

(9) Operating temperature of the coil: 0 to 100℃

(10) Inner diameter of the container: 600mm

(11) Chassis filtration area: 0.25 square meters

(12) Chassis filtration accuracy: 20-25μm(500-600 mesh)

(13) Total volume of the tank: 120L

(14) Stirring motor power: 2.2 kW

(15) Maximum thickness of the filter cake: 150mm

(16) Discharge valve diameter: DN200

(17) Total height of the equipment: < 2400mm