Application of Peristaltic Filling for Flexibility and Accuracy

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1 E03 - Aseptic Processing Technology 2008 Case Study: Application of Peristaltic Filling for Flexibility and Accuracy by Ted Kemnitz Automated Machine Technologies, Inc. AMT (919) Ted.Kemnitz@AMTLiquidFilling.com

2 Introduction to Servo Peristaltic Liquid Filling Liquid filling is a major element of Aseptic Processing Technology. This presentation highlights the advantages of using Servo Peristaltic Filling for Flexibility wide range of products and fill volumes Accuracy better than 0.5% with Servo Compensation Disposable Technology best suitable, minimal expense of product contact parts Lowest Contamination Risk - only peristaltic tubing contacts the product Piggyback System - easy and cost-effective integration into existing infrastructure

3 Aseptic Liquid Filling Desired Essentials Consistent Accuracy and Precision maintained throughout entire production with minimal set up Reduced risks of contamination with the lowest number of product contact parts that are easily exchangeable and can be disposable Eliminated dripping after fill via suck-back system Reduced splashing during fill by optimizing process parameters, such as number of nozzles, dispensing flow rate, nozzle and tubing sizes, bottom-up filling Flexibility with easy changeover to different products and fill volumes

4 Aseptic Liquid Filling - Desired Essentials Ability to interface with automatic SPC and PID process for 100% weight feedback Reduced risk of operator errors by utilizing exchangeable sets of fixed tooling in place of manual adjustments User-friendly operation based on simplicity and low maintenance Rugged system with long term consistency and reliability resulting in reduced downtime Easy integration with existing technologies and existing infrastructure for economical viability

5 Fig. 1. Servo Peristaltic Liquid Filling

6 Fig.2. Servo Peristaltic Liquid Filling Machine Cantilever type

7 Fig. 3 Servo Peristaltic Liquid Filling Machine Guards removed

8 Fig. 4. Servo Peristaltic Liquid Filling Machine Top view

9 Fig. 1. Servo Peristaltic Liquid Filling

10 Fig.5. Servo Peristaltic Liquid Filling Principle

11 Fig.6. Servo Peristaltic Pump Flow Characteristic

12 Servo Peristaltic Compensation - Principle Example: Integrating ml Dispense

13 Technology Base Incorporated in 1994 as Automated Machine Technologies, Inc. (AMT ), a manufacturer of packaging machines. Driven by demand for cost effective, high performance Servo motion controllers In-house Servo technology development, patents obtained Towards the end of XX century Computer Programmable Servo Systems were evolutionary breakthrough for high performance packaging machines.

CCL Industries, Toronto ON Development of environmentally friendly aerosol system 330 parts per minute citric acid dispensing precision of 0.5% Wide range of fill volumes, 0.

14 CCL Industries, Toronto ON Development of environmentally friendly aerosol system 330 parts per minute citric acid dispensing precision of 0.5% Wide range of fill volumes, 0.2 ml up to 12 ml Easy changeover and easy cleaning Original solution was urgently needed. While working with the new aerosol system, coincidently, an ideal product for Aseptic Liquid Filling was created.

Ciba Corning Diagnostic, Walpole MA Pilot production for diagnostics research High fill precision and easily programmable changeover to many different products and sizes Easily removable product

15 Ciba Corning Diagnostic, Walpole MA Pilot production for diagnostics research High fill precision and easily programmable changeover to many different products and sizes Easily removable product contact parts for autoclaving Adjustable diving nozzles with bottom-up control An answer was given to the demanding Ciba Corning needs with a two-axis servo peristaltic liquid filling machine and with a linear actuator for programmable nozzles.

Organon Technika, Durham NC Sterile liquid filling, stoppering and screw capping integrated into one system One system for over a hundred different products Precise and aseptic liquid dispensing

16 Organon Technika, Durham NC Sterile liquid filling, stoppering and screw capping integrated into one system One system for over a hundred different products Precise and aseptic liquid dispensing over wide range from 0.5mL to 1L Programmable calibration and changeover The flexibility of the Servo peristaltic pump became apparent when it was incorporated into the multifunctional monoblock system.

UDL Laboratories, Largo FL A manufacturer of Unit Dose Liquid Packs Existing system required frequent and difficult adjustments of all 40 individual pistons Lack of fill precision Difficulty in

17 UDL Laboratories, Largo FL A manufacturer of Unit Dose Liquid Packs Existing system required frequent and difficult adjustments of all 40 individual pistons Lack of fill precision Difficulty in cleaning piston cavities from sugarbased product Dripping nozzles due to low surface tension Problem meeting FDA regulations Large project on-hold until a solution could be found Servo peristaltic dispenser with compensated flow characteristic was the only answer to the complex demand for filling UDL Unit Dose Liquid Packs. Simplicity of the hardware allowed to build the custom machine economically and in a timely manner, saving the multimillion-dollar project. In fiscal year 2005, UDL shipped over 800 million doses and ranked as the number one generic unit dose supplier.

biomerieux, Durham NC A manufacturer of BacT/ALERT blood culture bottles Replacing glass container and 30mm stopper with new, cost-effective plastic vial with 20mm stopper for diagnostic blood

18 biomerieux, Durham NC A manufacturer of BacT/ALERT blood culture bottles Replacing glass container and 30mm stopper with new, cost-effective plastic vial with 20mm stopper for diagnostic blood culture bottles Filling through stoppers with 12 piercing nozzles in aseptic production Smaller stoppers require precise positioning of vials under piercing needles Easy changeover Increased fill precision Reduced risk for contamination With multi-axis capabilities, the Servo Peristaltic Pump was successfully integrated with a Servo-driven timing screw to precisely position the bottles under the needles.

19 biomerieux, Durham NC Servo Peristaltic Dispenser - Automatic SPC with 100% pre-fill/post-fill weight feedback

20 biomerieux, Durham NC A manufacturer of BacT/ALERT blood culture bottles Problems on the main production line: High maintenance Dripping nozzles Complicated and time-consuming adjustments Difficulties to maintain precise fill weights of +/-1% over 16 hours of continuous production cycle Disposable Technology and high fill precision at production rates over 300 vials per minute demanded SOLUTION: - Cantilever Servo pump for Disposable Technology - Nozzle-to-nozzle equalizing system with feedback - Automatic tubing wear compensation - Increased fill precision was maintained over 16 hour runs, and need for manual calibration was eliminated - Daily maintenance was reduced from hours to only a few minutes - FDA requirements were easily met with disposable product contact parts One year later, on November 26, 2007, biomerieux reported a 10% annual growth in the blood culture market.

21 biomerieux - Servo Peristaltic Data Variation [%] Silicone Tubing Grade Preformance on AMT 20-Nozzle Peristaltic Filler 1/8" ID 4 grams % Sani-Tech 50 Standard Grade Silicone Tubing Part No. STHT-C % Cole-Parmer Standard Grade Silicone Tubing Catalog No. K % Amesil Standard Grade Silicone Tubing Part No. ASTP125-4ELPF. 0.14% Dow Corning Pharma Advanced Nozzle # biomerieux: Servo Peristaltic Machine Model 239

Siemens Medical Solutions, Walpole MA Diagnostic Reagent Facility Expansion Increased and sustained fill precision throughout prolonged aseptic production On the fly calibration Monitoring of fill

22 Siemens Medical Solutions, Walpole MA Diagnostic Reagent Facility Expansion Increased and sustained fill precision throughout prolonged aseptic production On the fly calibration Monitoring of fill weights with the use of an automatic sampling system for SPC -- The Servo Peristaltic pump was the answer to - sustained precision and sterility -- The nozzle servo-mechanism was upgraded with - horizontal movements for automatic sampling A robust growth in the immunodiagnostics business is projected.

23 Siemens Medical Solutions - Servo Peristaltic Data Weight [G] 30 G fills with 8 nozzles Series1 Series2 Series3 Series4 Series5 Series6 Series7 Series8 Sample # Servo Peristaltic Machine Model 150

24 Siemens Medical Solutions - Servo Peristaltic Data [%] 100%*(Sample-Mean)/Mean 30 G fills with 8 nozzles Series1 Series2 Series3 Series4 Series5 Series6 Series7 Series Sample# Servo Peristaltic Machine Model 150

25 Siemens Medical Solutions - Servo Peristaltic Data Variation [%] Fill Precision across 4 Nozzles 1/32" ID 0.5 grams Sample # % Nozzle % Nozzle % Nozzle % Nozzle Servo Peristaltic Machine Model 150

26 Catalent Pharma Solutions, Raleigh, NC Disposable Technology Fill Precision +/- 0.5% Flexibility with easy changeover Volumes 0.5 ml to 1000 ml Portable machine, easily integrated with Bosh TL system Cantilever Servo Peristaltic Pump was configured into a portable machine and designed for Disposable Technology.

27 Catalent Pharma Solutions - Servo Peristaltic Data Produced: 02/04/08 Sample Deviation [G] [%] Mean Variattion [%] Fill Precision 1 Nozzle 1/16 ID 5 grams Fill Weight [g] Fill Weights 1 Nozzle 1/16 ID 5 grams Sample # Sample #

28 Catalent Pharma Solutions - Servo Peristaltic Data Produced: 02/13/ [%] 100%*(Sample-Mean)/Mean 12 Nozzle Servo Peristaltic Model [G] dispense Sample # Nozzle 1 Nozzle 2 Nozzle 3 Nozzle 4 Nozzle 5 Nozzle 6 Nozzle 7 Nozzle 8

29 Fig Nozzle Servo Peristaltic System

30 Fig. 8. Piggyback Servo Peristaltic Dispenser incorporated into Filling & Stoppering Monoblock Machine

31 Fig. 9. Servo Peristaltic 384-Well MicroPlate Dispenser From 0.5 ul to 0.5 ml; CV=1%

32 Fig. 10. Servo Peristaltic MicroPlate Fig. 11. Peristaltic Micro Pump

33 Fig. 11. Disposable Cartridge for Servo Peristaltic MicroPlate Dispenser

34 120.0 Flow Rate per Nozzle RPM Tubing ID [inch] Servo Peristaltic Machine

35 Absolute Error [ml] Tubing ID [inch] Servo Peristaltic Machine

36 250.0 Bottles per Tubing ID=1/32" 8-Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

37 400.0 Bottles per Tubing ID=1/16" Nozzles Nozzles Nozzles Nozzles 1-Nozzle 1.83 Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

38 Bottles per Tubing ID=3/32" Nozzles Nozzles Nozzles Nozzles 1-Nozzle 1.43 Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

39 Bottles per Tubing ID=1/8" Nozzles Nozzles Nozzles Nozzles 1-Nozzle 1.56 Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

40 Bottles per Tubing ID=3/16" Nozzles Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

41 Bottles per Tubing ID=1/4" Nozzles Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

42 Bottles per Tubing ID=5/16" Nozzles Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

43 Bottles per Tubing ID=3/8" Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

44 Bottles per Tubing ID=1/2" Nozzles Nozzles Nozzles Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

45 Bottles per Tubing ID=5/8" Nozzles Nozzles Nozzles 1-Nozzle Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

46 80.0 Bottles per Tubing ID=3/4" Nozzles Nozzles Nozzles 1-Nozzle 1.06 Tolerance[%] Fill Volume [ml] Servo Peristaltic Machine

47 0.8 Fill Precision across 4 Nozzles 1/16 ID 1 gram Variattion [%] % Nozzle % Nozzle % Nozzle % Nozzle 4 Sample # Servo Peristaltic Machine

48 1.2 Fill Precision across 8 Nozzles 1/16" ID grams Variation [%] % Nozzle % Nozzle % Nozzle % Nozzle 4 Sample # 0.654% Nozzle % Nozzle % Nozzle % Nozzle 8 Servo Peristaltic Machine

49 0.6 Fill Precision across 8 Nozzles 1/8" ID 10 grams Variation [%] % Nozzle % Nozzle % Nozzle % Nozzle-4 Sample # 0.33% Nozzle % Nozzle % Nozzle % Nozzle-8 Servo Peristaltic Machine

50 Fill Precision across 8 Nozzles 1/8" 30 grams Variation [%] % Nozzle % Nozzle % Nozzle % Nozzle-4 Sample # 0.84% Nozzle % Nozzle % Nozzle % Nozzle-8 Servo Peristaltic Machine

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