Permission to change and develop in the Life Sciences!

20/06/2017
• Enjoy a unique environment to meet and gain input from all stake holders on industry direction, challenges and solutions.
• Shape your strategy on the way solutions should be developed and applied in your facility
• Understand how partnering can take you further, faster and with reduced risk
• Experience hands on demonstrations of automation equipment and packages.

The invitation was interesting, and challenging. “Future.Now – Developing the Life Sciences Landscape Together” was an arresting title. It was a co-operative event between National Institute for Bioprocessing Research and Training (NIBRT) and Emerson. We were invited to “Boost your knowledge, gain from the experience of others and increase your professional network at NIBRT state of the art facility in Dublin!”

Mike Train, Executive President with Emerson explains their focus under the attentive eye of European President Roel Van Doren.

This correspondent was aware of the NIBRT facility but had very little idea of what it was real function or its relevance to Irish industry. This was an opportunity find out. Further looking through the programme two things became apparent. One was the calibre of personnel speaking from the Emerson organisation and then the application rather than product orientation of the various sessions.

It proved to be a very interesting two days.

Day 1: Working together towards a common future.
Presentations from NIBRT, Industrial Development Authority (IDA), GSK, Alexion, Zeton, Novo Nordisk and Emerson Automation Solutions.

Pharma v Biopharma

After a short welcome fro Emerson Europe President, Roel Van Doren, the CEO of NIBRT, Dominic Carolan, outlined the foundation and raison d’etre of the organisation. It is a training and research in the area of bioprocessing. It is located in a new, world class facility in Dublin (IRL). As medical science advances “simple” chemistry, while still essential, is not fully capable of solving all health issues – Pharma versus Biopharma. Bioprocessing is a specific process that uses complete living cells or their components (e.g., bacteria, enzymes, chloroplasts) to obtain desired products.

Thus this facility exists to support the growth and development of all aspects of the biopharmaceutical industry in Ireland. It is purpose built to closely replicate a modern bioprocessing plant with state of the art equipment.

Making Ireland ready – a good news story.
Dr Chantelle Keirnan, Scientific Advisor with the Industrial Development Authority (IDA), described the far-seeing intuitive initiative to look at bioprocessing “before it was profitable or popular!” This state body is responsible for the attraction and development of foreign investment in Ireland and had been extraordinarily successful in attracting nine of the top ten pharma companies to set up manufacturing processing plants in Ireland. They considered at the turn of the century that bioprocessing was the way that life science was going and took steps to ensure that Ireland was ready. One of those steps was the provision of Government funding of NIBRT.

Togged out for the tour

Many of the delegates – in excess of one hundred attended some from other countries – donned white coats and took the opportunity to tour the impressive facility during the event. It includes a purpose-built, multi-functional building which replicates the most modern industrial bioprocessing facility. Some idea of this facility may be gleaned from their website here.

This is a good news story. How often are decisions of state organisations regarded, not entirely without justification, with a jaundiced eye? Those that are good are “oft interréd with their bones!” The vision that saw this development in industry and the individuals who having caught the ball ran with it and brought it so successfully to fruition is worthy of equal attention and praise.

The rest of the day was an examination of the industry, processes and looking into the future. Mike Train, Executive President of Emerson spoke on the changes that are influencing industry and his company’s focus. We are facing “an evolution not a revolution” he stated, a point emphasised by other speakers throughout the day. He also stressed the importance for giving permission to change. (See full list of speakers at below.)

Pictures from the event!

We then had a series of speakers from the industry, people who get their hands dirty so to speak in actual processing speaking of their experiences and challenges. Speakers from GSK and Novo Nordisk explored areas like partnership, legacy issues, building on or expanding existing plants, saving energy, wireless. There was some discussion on the cloud and its advantages and just how vulnerable it might be to security breaches.

The discussion on handling all this data and identifying and retrieving those pieces of data which are really useful to the process brought to mind the prophetic words of the American media theorist, Neil Postman years ago, “…a central thesis of computer technology – that the principal difficulty we have in solving problems stems from insufficient data – will go unexamined. Until, years from now, when it will be noticed that the massive collection and speed of light retrieval of data have been of great value to large scale organisations but have solved very little of importance to most people and have created at least as many problems for them as they have solved…” (Neil Postman: “Amusing ourselves to death:” 1985)

Peter Zornio, Chief Technology Officer with Emerson gave their philosophy in meeting the demands of “Life Science Visions.” He lauded the various discussion groups such as the Biopharma Operations Group in helping how to keep up to date with technology and fostering new ideas.

We are on a digitizing journey. Moving from manual and paper to digital recording and control.

Day 2: “New Technology, New Processes, New solutions!”
Presentations from BioPharmaChem, GSK, Infinity Automation and Emerson.

The day started with a presentation on modular flexible manufacturing – introducing the PK Controller and a little later in the day there was an exposition on DeltaV Discovery/DeltaV 14 in maintaining data and transferning and easing technology transfer through the life cycle of drug development.

In his second presentation Peter Zornio gave the business case behing IIoT. IoT is usually referring to domestic, building environment and other civil applications. But it is also useful in the industrial environment where it is referred to as IIoT. Initially it was a link up at the instrument and control area but of late it is spreading to the portfolio of sensors. Their emphasis is on “the first mile!” (This is a backward reference to the perennial problem in many, especially rural, areas of “the last mile” – the internet connection directly into the home! – a heart felt sigh from your correspondent!)

The Real Challenges!

Ian Allen of Infinity Automation spoke on challenges to the life science automation world. “Don’t go backward to go forward” he said. We must use things like data integrity, cyber security, Microsoft dependencies and Industrie 4.0 as “gifts to leverage the opportunity and change!” The real challenge is not so much the technology but our use of it. We were coming back to “permission for change!”

We might perhaps use the words of the Bard of Avon, “The fault, dear Brutus, is not in our stars. But in ourselves….”  The “gifts” are there. The Technology is there or on the way.

Let’s own these gifts and make them our own.

 

Pic: Travis Hesketh


The Speakers:

Day 1
Dominic Carolan
CEO – NIBRT
Dominic Carolan was appointed CEO of NIBRT in April 2015. Mr. Carolan previously held senior roles in Mallinckrodt (Dublin), Genzyme (Waterford), also Genzyme (Corporate) where he was Senior Vice President of Manufacturing, and in Sanofi, where he headed their global network of Sterile Injectable Lyophilisation sites. He has successfully lead the startup of two significant Pharma & BioPharma facilities in Ireland and has a proven track record in operations leadership and in attracting and developing the talent required to deliver long term success. A graduate of UCD in Chemical Engineering, Mr. Carolan was Chairman of BioPharmaChemical Ireland from 2008-2010.
Dr Chantelle Kiernan
Scientific Advisor – IDA

Dr. Chantelle Kiernan joined IDA in September of 2009 and is responsible for attracting research related foreign direct investment for Ireland. Chantelle has responsibility for the Multinational research portfolio – spanning Pharmaceutical, Biotechnology, Medical Device, Engineering Food services industries. Chantelle has spent her career equally dispersed between academia and industry. She holds a PhD in Immunology from Trinity College Dublin in the area of immunomodulation and continued her academic career with a Post-Doctoral fellowship in Harvard University, Boston. Chantelle is currently undertaking an MSc in International Business law. She has spent almost fifteen years in industry. In her current role as Scientific Advisor for the IDA, she has been integrally involved in attracting and securing large scale R&D foreign direct investments for Ireland.

Mike Train
Executive President – Emerson Automation Solutions
Michael H. Train leads the Automation Solutions business of Emerson, which posted sales of $10.2 billion in fiscal 2015. Train began his career with Emerson in 1991 as an international planner, then took on additional responsibilities in a number of executive posts that included serving as President of Emerson Japan and Korea, VP of Corporate Planning, President of Emerson Process Management Asia Pacific, and President of Emerson’s Rosemount business. He was most recently President of Global Sales for Emerson Process Management, responsible for sales, service, support, and customer satisfaction for all products and services across five world-area organizations. In that role he was also part of the leadership team that drove strategic initiatives and investments for the entire business group. Train earned a bachelor’s degree in electrical engineering from General Motors Institute and an MBA from the Johnson Graduate School of Management at Cornell University. He currently serves on the management school’s advisory council and was a 2008 Eisenhower Fellowship recipient.
Dave Tudor
Vice President, Head of GMS Strategy – GSK
Dave joined GSK in 1992 at Worthing as a PhD Chemist from Glasgow University. He has over 20 years’ experience with the company carrying out a number of Technical, Compliance and Manufacturing leadership roles. In 1997 he moved to Irvine to take up a lead chemist role before coming Quality Control Manager in 1998. He joined the site leadership team in 2001 to run Technical Development before moving to manufacturing as Actives Production Director in 2005. During this time he completed a Masters degree in Manufacturing Leadership at Cambridge University. In 2007 he moved to GSK House to work on a central network re-structuring project before becoming Site Director at Montrose in October 2008. At Montrose, he led the transformation of the site to manufacture over 12 products for GSK including a major investment programme. In 2011 he was appointed VP Primary Supply Chain with responsibility for global Active Pharmaceutical Ingredients (API) manufacture and supply, a network of GMS sites across the world including facilities in Asia and Europe. In 2017 he was appointed VP Head of GMS Strategy with responsibility for manufacturing strategy, deployment of strategic programmes, performance management and advocacy. He plays an active role with a number of Governments and is currently co-chair of the Life Sciences Scotland Industry Leadership Group. Dave is also a member of UK Chemicals Industry Association Council and Board. Dave is married with 4 children and lives in Troon, Ayrshire. He enjoys all sports, particularly football, is a keen reader of Scottish history and does cooking to relax.
Peter Zornio
Chief Strategic Officer – Emerson Automation Solutions
As Chief Strategic Officer for Emerson Automation Solutions, Peter has responsibility for overall coordination of technology programs, product and portfolio direction, and industry standards across the Automation Solutions group. He has direct responsibility for the product definition and development organizations for control systems and software products. He has been at Emerson for 10 years. Prior to Emerson, he spent over 20 years at Honeywell in a variety of technology and marking roles, most recently as overall product management leader. Peter holds a degree in Chemical Engineering from the University of New Hampshire.
Herman Bottenberg
Marketing Director,, Zeton

PDEng. Ir. Herman Bottenberg is a chemical engineer with 15+ years of industrial experience, along with two years of Post academic work on Plant Design. He worked for 17 years at Zeton B.V. in The Netherlands, with five years of experience in project engineering and project management. The last 12 years he has been active in business development, sales and marketing. Since 2016 Herman is also responsible for the Marketing and Sales group at Zeton B.V. Herman has specialised in transformation of processes from batch to continuous, process intensification and modular processing plants for pharma and chemical industry.

Day 2
 Matt Moran
Director – BioPharmaChem Ireland
Matthew Moran is Director of BioPharmaChem Ireland. He graduated in Chemistry at Trinity College Dublin in 1980 and in Chemical Engineering at University College Dublin in 1981; he holds an MBA also from University College Dublin (Smurfit School of Business). He worked for over ten years in the pharmaceutical industry where he held a number of management positions both in active ingredient and dosage form manufacture. He is a member the European Chemical Industry Council (CEFIC). Matthew Moran is a Board member of the Active Pharmaceuticals Ingredients (API) Committee of CEFIC (CEFIC/APIC) and The European Association for Bioindustries (Europabio) BioPharmaChem Ireland represents the interests of the biopharmachem sector in Ireland. CEFIC/APIC represents the European API Industry. Europabio represents the European Biotech Sector.
Ian Allan
Automation Consultant – Infinity Automation
Currently the Managing Director of Infinity Automation, a relatively new company carrying out Automation & MES Consultancy, Strategic Planning and Major Program/Project Health checks, with blue chip Global Life Science companies and Strategic vendors that support that Industry. Formerly Ian was the Global Head of Automation & MES with Novartis, where he was responsible for the Manufacturing Automation Strategy and MES Program within Technical Operations in the Vaccines division.  Prior to that he worked for GSK as Global Automation Director responsible for Automation, Process Control and MES across 73 sites worldwide. There he led a team that developed a library of Emerson DeltaV modules to be deployed in multiple Bulk API sites across the world, as well as developing a blueprint for MES integration and Network delivery of Electronic Batch Records. Prior to that he held several roles in GSK within the Engineering and Automation departments. Ian started his career with IBM as a junior engineer when computers were a little bigger than they are today and holds a BSc in Electrical & Control Engineering from Strathclyde University. He is currently facilitating GSK’s Global Automation Steering Team and is leading the Digital Factory Automation workstream for a new Hybrid Manufacturing platform with the first instance being delivered in GSK Singapore Jurong site.
Colin Chapman
Director of Manufacturing IT – GSK
Colin Chapman is a Chemical Engineer with nearly 20 years experience in Life Sciences with GSK. Colin’s career has spanned across process engineering & automation, operations and new product introduction in both commercial manufacturing and clinical supply chains. In his current role as Director of Manufacturing IT Colin has successfully led the introduction of Manufacturing Operations Management across the clinical supply chain driving business process re-engineering and global workflow automation using technologies such as Syncade. GSK’s continuing program focuses on three value drivers, Compliance, Business Intelligence and Productivity.
Klaus Erni
Product Manager & Namur 148 Board Member – Emerson Automation Solutions
Klaus started his Emerson career in 2003 in Germany, where he was working as a Technical Manager for Key Accounts before he transferred to Austin, TX to become the DeltaV Hardware Product Marketing Manager. In 2015, he went back to Europe and took over another Global Role, being now the Technical Consultant to some major Strategic Accounts. While in Germany with Emerson, he was responsible for the technical aspects of the DeltaV Systems during the Sales and Implementation Phase, as well utilizing the latest Hardware and Software features while upgrading and expanding Systems on Key Customer sites. Prior to Emerson, Klaus was with the Hoechst AG, he did several Engineering projects with various PLC and DCS and SIS Systems and was as well a RS3 System User.
Danny Vandeput
Director Pervasive Sensing Strategies – Emerson Automation Solutions
The (Industrial) Internet of Things (IIoT) is revolutionizing the way we live but it also provides many new challenges to the industry. This can create confusion, uncertainty – combined with fuzzy statements – and different opinions. My great passion is to bring clarity in the Industrial Internet of Things and what benefits it can bring for you. I help industries to find the right perception of IIoT, how sensors can maximize profit, reduce downtime and bring the ROI into the IoT. Being already 23 years with Emerson I have assisted many types of industries on their way to Top Quartile Performance. This includes amongst other trainings, workshops, audits and implementing solutions.
#PAuto @EMR_Automation @NIBRT_ #IIoT @HHC_Lewis

450 blisters per minute!

18/06/2014
PLC, motion control, drive as one unit: A complete solution for PG Express described by Alexander Hack, Market Development Manager,Kollmorgen, Ratingen (D). Bringing in latest technological innovations, Kollmorgen is participating in strengthening the packaging & metal forming market segment in a big way.
Alexander Hack

Alexander Hack

It is in this pursuit of excellence, Kollmorgen has supplied the complete automation solution to IMA PG for their PG Express machine. IMA-PG India Private Limited is a pioneer in the field of Thermoforming machines in India having introduced its first machine in 1978. It is today well-respected for its ability to innovate and engineer solutions to meet constantly changing demands. It offers a complete range of packaging solutions that includes machines for applications such as cartoning, rotary vacuum forming, rotary sealing, flat sealing and tube-filling besides of end-of-line packaging. Kollmorgen has been associated with IMA PG for the last two years where they have supplied Automation Solution products like Motion Controller, HMI, Servo drives, Servo Motors, I/Os, etc. Through world-class knowledge in motion, industry-leading quality, and deep expertise in linking and integrating standard and custom products, Kollmorgen provides OEMs with the competitive advantage they need to succeed.

AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines.

AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines.

It is in this pursuit of excellence, Kollmorgen has supplied the complete automation solution to IMA PG for their PG Express machine. IMA-PG India Private Limited is a pioneer in the field of Thermoforming machines in India having introduced its first machine in 1978. It is today well-respected for its ability to innovate and engineer solutions to meet constantly changing demands. It offers a complete range of packaging solutions that includes machines for applications such as cartoning, rotary vacuum forming, rotary sealing, flat sealing and tube-filling besides of end-of-line packaging. Kollmorgen has been associated with IMA PG for the last two years where they have supplied Automation Solution products like Motion Controller, HMI, Servo drives, Servo Motors, I/Os, etc. Through world-class knowledge in motion, industry-leading quality, and deep expertise in linking and integrating standard and custom products, Kollmorgen provides OEMs with the competitive advantage they need to succeed.

PG Express – a backgrounder

The machine can now produce upto 450 blisters per minute thus making production much faster. Currently the P G Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months...

The machine can now produce upto 450 blisters per minute thus making production much faster. Currently the P G Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months…

PG Express machine is a blister packaging machine which is used for forming blisters. Blister is a pack of some tablets (e.g. 10, 4, 5, 1 etc.) made as per design which is used to hold the tablet. This machine is manufactured by IMA PG from the last three to four years but this was the first machine where Kollmorgen supplied the entire automation solution. It is a 3 axis machine used for Indexing, feeding and punching the blister. Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister. Kollmorgen has improved the machine speed through excellent system performance. The machine can now produce upto 450 blisters per minute thus making production much faster. However, the OEM started developing obstacles in controlling the temperature which is a critical aspect of this machine because sealing is dependent on the effective temperature control. If the temperature is not controlled properly then the quality of final blister would be bad & it won´t be sellable in market.

Reliability right from the start
When the OEM approached Kollmorgen with this problem, they were quick to respond. An inbuilt function for temperature control was installed which is around 15 times faster than the external controllers. This saves additional PID controller  costs and more importantly it results in better quality and less wastage.

The program is controlled using AKD PDMM controller. This is a drive based motion controller with integrated PLC functionality, which is specially designed for small and compact machines typically used in packaging machines. AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines. The integrated Motion Controller can synchronize up to 8 axes with 250 µs cycle time. It supports various motion control functions from simple point to point positioning to linear and circular interpolation. PDMM can take care of PLC logic, temperature control, motion control, HMI control & drive control for entire packaging machine.

To allow the highest flexibility and freedom of programming, Kollmorgen Automation SuiteTM software has been used where PLC logic, HMI programming, Motion control & drive control are all integrated at one place. It complies with IEC 61131-3 standard for programming languages.

To make the machine user friendly for the OEM, easy software development was done using the Pipe NetworkTM which is one of the key differentiators by Kollmorgen. The software development was done in just 10 days as compared to 45 days by competitors thus saving valuable time and money for the client. With the Pipe NetworkTM it is possible to get rid of mechanical components (e.g. gear, cam) in the machine by defining equivalent motion blocks in the software. This is extremely user friendly, easy to implement & easy to troubleshoot. The user simply needs to draw the scheme & ultimately connect to the machine axes as per requirements. All necessary interconnections are done automatically in the program. The biggest benefit for programmer & end user is the ease of programming & troubleshooting with clear visual understanding of the scheme.

After-Sales Service & Support
At Kollmorgen, the »after sales service and support» to the customer is of prime importance. In this case the first commissioning of the machine was done with the help of global expertise in this kind of application.

Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister.

Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister.

Senior application development engineers from Germany did the entire conceptualization & programming. It was because of the hard work and dedication of the Kollmorgen team that the actual time for conducting trials & finalizing the performance took just 10 days (against 45 days taken by competitor).

Currently the PG Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months. From the beginning, Kollmorgen has kept a dedicated application & sales engineer for IMA PG.

After the successful implementation of this machine, Kollmorgen subsequently got two new prototypes- PG Super & C350 and successfully executed the same. It was a moment of pride when Kollmorgen recently got the serial production orders for PG Express.


Quieter, more efficient, and improved controllability!

02/06/2014
Dr. Petr Osipov, Product Management Motors, Kollmorgen (D) tells how Multivac relies on Kollmorgen for pneumatic to electric transition

An increasing number of companies in the packaging machine industry have chosen electrical servo technology – mainly to replace motion axes previously powered by pneumatic systems. “Servo technology increases controllability and reduces noise emission. These systems also help us to increase the number of production cycles”, Guido Spix, CTO Multivac, recently emphasized during a packaging show. The packaging machine company uses motion control solutions from Kollmorgen to reduce energy consumption, increase the overall machine effectiveness and improve safety of packaging processes.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Optimised motorgear box combination.

Optimised motorgear box combination.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw and seal the foils.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw & seal the foils.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

Kollmorgen was able to cover most of the transportation and rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

Kollmorgen was able to cover most of the transportation & rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

The AKMH™ stainless steel motors (http://www.kollmorgen.com/en-gb/products/motors/servo/akmh-series/akmh-stainless-steel-series/) provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

The AKMH™ stainless steel motors provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

Secure packaging:
Besides machine and operator safety, for Multivac, this also includes safe packaging processes. The excellent traceability and controllability of Kollmorgen’s servo technology for example, helped Multivac to design a more efficient sealing process for deep drawn packages with the additional benefit of improved food safety. This solution is currently used on the high performance deep draw machines, designed for mid-size to large loads.

Compared to traditional mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilize a motor-gearbox combination to deep draw and seal the foil. These units utilise a knee lever mechanism to lift the molding tools – some weighing several hundred kilograms. They withstand the high bonding pressure of up to 20 tons, ensuring the two foils seal securely. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit consisting of an AKM® servo motor  and a cycloidal gear drive for the lifting axis. Kollmorgen calculated and selected the optimal motor size and gear drive type in close cooperation with Multivac’s engineering development teams.

Two important aspects for the drive train selection were the overall unit length and overload capacity. The model HKS03 six-point lift unit features a servo gear motor with brake having a total length of 307mm and an acceleration torque of 1400 Nm. These results are possible thanks to the high power density of the AKM servo motors, the ideal overall length of the cycloidal gear drive and the fact that the unit comes without end bells and clutches. Piston rods convert the rotary to linear lifting motion. This solution has three significant advantages. Firstly, the energy efficiency of the machine increases because the pneumatic system was replaced as the power source to create the required pressure for the deep draw and sealing operation. Secondly, the geometry of the piston rods creates an extreme closing force at the end of travel which improves food safety. Finally, the high sealing force results in a more secure and thus reliable sealing process.

“Perfectly Clean” inside and out
The two-component epoxy coat used for the hygienic design conforms with FDA 21 CFR 175.300 and is resistant against acids, bases and established cleaning agents with a pH range of 2 to 12. In a long term test performed by the company EcoLab, this coat withstood exposure to an equivalent of more than 2000 washdown cycles including disinfecting treatments. Kollmorgen’s washdown gear motor comes standard with a white coating, significantly improving the machine operators’ ability to detect dirt and biofilms on the surface during cleaning operations.

A stainless steel-like coating is offered as an option. The surface of both coats is water repellent (hydrophobic) and aqueous liquids will run off more easily, which leads to decreased formation of residue on the surface. Hence, Kollmorgen’s standard of a “perfectly clean” gear motor can seamlessly be incorporated in the MULTIVAC Hygienic Design™ concept that is rigorously applied to all deep draw packaging machines.

From Co-Engineering to Production
Multivac has a global distribution network with about 60 subsidiaries and offers a variety of different machine models with different features. Managing this variety with extensive standardization requires strategic partners that are able to cover a large range of machine applications with their technologies. The Kollmorgen washdown gear motor solution is a perfect example for how a project based custom-designed and custom-built product becomes a standardized, ready-to-install module. The concept of the current motion and automation technology used on the deep draw machine follows the requirements of the new Multivac solution: more flexibility by being able to combine several axes interchangeably and at the same time, smaller control units, plus an increase in dynamic performance for better productivity. In summary, thanks to Multivac’s and Kollmorgen’s close cooperation in this project, the entire pneumatic system was replaced by a highly efficient electrical solution. After the first successful practice runs, Multivac determined a reduction in energy consumption for the R 095 e-concept of at least 20 percent compared to similar models.


Growing process industry demands for meeting standards

03/04/2012
Meeting the demands of a growing world

An expanding global population and rising living standards are fueling demand in the process industries. Requirements for safety, quality and performance mean growth for Trelleborg.

From food to pharmaceuticals, chemicals to petrochemicals, processing companies strive constantly to increase efficiency and reduce waste and maintenance costs while meeting ever more stringent environmental and product safety regulations.

Though many industrial sectors were heavily impacted by the global downturn, the food, beverage and pharmaceutical industries have been relatively unscathed.

“The world population is growing, and more people have access to processed food and medicines, so this market is showing consistent growth,” says Ferdinand Schwabe, Food, Beverage & Pharmaceutical Segment Manager Europe, at Trelleborg Sealing Solutions. The company supplies a wide range of static, linear and rotary seals in polymeric materials to food, beverage and pharmaceutical producers globally.

For hygenic applications

Not only are convenience foods in greater demand today, but an increasing level of health consciousness among consumers has resulted in processed foods that are lower in fat and sugar, and this creates food safety issues.

“Sugar is a preservative, so products that contain low amounts of sugar are often more susceptible to microorganisms,” says Schwabe. “As microwave food is only heated up briefly, pathogenic micro-organisms are not killed, and this raises hygiene requirements within the industry.”

The need for hygienic design to ensure product safety while maintaining economic efficiency is affecting demand for Trelleborg’s products. For one thing, customers need materials and components that can handle higher temperatures. “Hygienic design is a big issue within the food and pharmaceutical industries,” Schwabe says. “This puts big demands on the seals. For example, manufacturers want to increase cleaning temperatures from 80°C to 140°C to make cleaning more effective. Our seals must handle these conditions.” These trends keep Trelleborg’s R&D departments busy, with customers calling for solutions that fulfill hygienic design requirements and meet food contact regulations.

“Business is growing,” Schwabe says. His segment recently had its best month ever, and Schwabe says he expects the trend to continue. “A leading player like Trelleborg finds it easier than other companies to meet the costs of developing and testing the special compounds required to fulfill legal and quality management requirements.”

The chemicals industry, one of the largest sectors in the process industry, is a US$ 3.7 (€2.77) trillion  global enterprise that is continuing to grow. European and U.S. chemical companies remain the world’s largest producers, but China and India are the main growth markets, and Western companies are investing heavily there.

Olivier Libes is the Marketing & Product Development Manager for Trelleborg in Clermont-Ferrand (F), which supplies many of the world’s major chemical producers with hoses. It recently opened an office in China west of Shanghai. This migration is not a case of outsourcing production but rather of moving to where demand is. “Western companies are establishing themselves in China, and they know what they want in terms of component quality and performance, so we are now there to provide them with our solutions.”

Spills and accidents at chemical and petrochemical production facilities in recent decades have highlighted the need for high-quality components and systems. “A malfunction in these industries can cause extreme environmental issues, so companies are looking increasingly towards high-performance products,” Libes says. “This is where Trelleborg is strongest and where we can develop our business. So this is a very promising area for us.”

Keeping us safe

Frederick Accum

We expect food and beverages to be safe, but food safety has not always been assured. As early as the 1820s, chemist Frederick Accum raised the alarm about food adulteration. He highlighted cheap versions of expensive tea and coffee made from used tea leaves boiled with sheep’s dung and exhausted coffee grounds mixed with sand and gravel. Worst of all were poisonous colorings used in candy to attract children that contained lead, copper or mercury salts. (see “The Mutually Poisoning Society” for more on Accum’s campaign!)

Following on from this work, Thomas Wakley, surgeon, British MP and founding editor of the medical weekly The Lancet, started a long campaign against the adulteration of food and drugs to secure legislation to protect the public. He worked with London-based physician Arthur Hill Hassell, who during the 1850s proved that adulteration was the rule rather than the exception.

Today, regulations are tight controlling the processing of anything that will be consumed by people. Bodies such as the U.S. Food and Drug Administration (FDA), Britain’s Food Standards Agency and the European Commission, among others, set and administer standards globally. As polymer components are used within processing systems in contact with foodstuffs, numerous standards are applicable to them and compounds are specifically formulated to be compliant.

On the floor
Forklifts are widely used in the processing industry to move materials, transfer products between locations within a facility and load trucks. Trelleborg is a leading supplier of industrial tires for forklifts and other industrial applications. Its products include a wide range of tires with high durability and excellent grip supplied through the brands Bergougnan, Monarch, Rota and Trelleborg.

The perfect match
It doesn’t matter whether a polymer is used in a seal, hose or other component within a processing system, the material will always face the same issue of media compatibility. Making sure that a polymer is able to withstand the media that is processed or the media with which the system is cleaned is vital in ensuring length of life and effectiveness.

The wide variety of food, beverages and chemicals that are processed along with stringent cleaning-in-place regimes, now normal practice in hygienic industries, have led to the development of a wide range of polymers. Making sure the polymer selected is a perfect match for the processing conditions is no easy task. A material that works well with one medium being processed may not work well with another.

The company undertakes extensive testing so it can recommend the perfect match of polymer to system and cleaning media. This information is then used in compatibility data available either in printed form or via online tools.

Technology on the inside
From the outside one hose looks much the same as another. Beneath its outer surface, though, advanced technology makes these vital lines integral to any processing system. Innovative rubber hoses are used throughout the food industry. Whether for transferring milk from farm to factory, for washing down food production areas or for filling barrels with wine, food-use hoses play a key role in the production of virtually everything we eat or drink.

Wine
Due to requirements of the different processing areas, hoses tend to be developed specifically for each application. For instance, Vinitrell is a hose developed by Trelleborg Engineered Systems especially for the wine industry. It offers the superior benefits of a rubber product, while its advanced polymer coating allows it to move as easily as a PVC hose around wineries.

Keeping wine safe!

“Rubber hoses have significant advantages over PVC products,” says Christine Dhiersat, Product Manager for performance hoses at Trelleborg in Clermont-Ferrand, France. “These are the maintenance of pressure and flexibility over the whole of their operating temperature range and absorption of impact. Their disadvantage is that they are heavier and sometimes difficult to maneuver within wineries.” Vinitrell, with its unique polymer coating, solves this problem, and many wines in Bordeaux, Champagne, Languedoc-Roussillon, Rioja and Ribera del Duero are already flowing freely through these hoses. For its annual production of 5 million bottles, the wine cooperative UDPSE in Saint-Emilion (F), uses Trelleborg hoses.
“The key to a great wine is quality, which you get from treating wine with respect. We only use hoses from Trelleborg and have over 1,500 meters at present,” says Bertrand Bourdil, Technical Director at UDPSE. The hoses are utilized wherever the wine needs to be transferred, such as from the vats to the barrels.

Milk
For transfer of milk there is the Lactadial. Milk trucks can make as many as 50 milk stops per day, which is not a problem when they are equipped with automatic rollers to extend and recoil the hoses. However, many drivers are obliged to manipulate the hoses themselves, which can make for backbreaking work. “Lactadial uses new polyesters,” explains Dhiersat. “This not only makes it 20 percent lighter than previous hoses for milk transfer, but also offers much better resistance to fatigue.”


Emerald shoots…!?

22/05/2009

Pharma industry waters Ireland’s green shoots!

The Taoiseach (Head of Government of Ireland) yesterday said something that sounds like an optimistic statement about our economy!
“….I want to explain to you tonight that we are making real progress, and that we have a way out that is working,” Mr Cowen said.

Taoiseach Cowan presents some Irish green shoots!

Taoiseach Cowan presents some Irish green shoots!

“And it’s not just me or my party colleagues who are saying that. The ESRI (Economic & Social Research Institute) and other commentators are now predicting that the decisions taken by the Government, allied with the flexibility of our economy and our people in reacting to the crisis, means that we are positioned to return to growth, even rapid growth, as the world economy turns, as early as next year….”

As Charles Dickens might have said, “a consumation devoutly to be wished!” though as opposition party spokespeople pointed out, there is an election (for Local Authorities and European Parliament) on June 5th 2009!

Coincidentally, we received the latest PharmaManufacturing.com e-news yesterday evening which headlined, “Irish Pharma Weathers the Storm with Innovation!”. I had not heard the Taoiseach’s remarks when it arrived so naturally, as an item of good news, and particularly good news about Ireland I clicked all the relevent links!

Ther are two articles there on Ireland. One a sort of colour piece on Ireland entitled “Enterprising Ireland: a Video Travelogue”. The by line says “Even during very challenging economic times, Ireland sees its focus on quality and innovation and an excellent scientific workforce as distinct competitive advantages. Senior digital editor Michele Vaccarello Wagner recently toured the island and interviewed some of those who are moving its life sciences agenda forward.”

Essentially it is the impressions of the writer on her visit to Ireland during which she visited a number of enterprises. That Ireland should be visited by a journalist from a pharma publication is not that remarkable since she is one of the pharmaceutical industry’s leading manufacturing bases and has attracted huge levels of investment from the industry despite having little tradition of domestic manufacturing. Most Big Pharma companies have production facilities all over the country. More recently there have been some job losses here as markets changed and manufacturing opportunities opened in other parts of the globe. Nevertheless as Ms Wagner says, “… many new investments have been made in Ireland, particularly in the biotech field. Companies such as Pfizer, Wyeth and Amgen have invested millions in establishing new biotech plants in Ireland in recent years, helping create permanent jobs and further stimulate the economy.”

In all she spent a good week here visiting plants and educational establishments in the south and east of the country. As an Irish person I find it interesting to get “another angle” on things as she see them.

The second article is an interview with John Clark of Athlone Laboratories, a plant in the middle of the country. As generic manufacturers take on increased importance in global pharma, serialization and track and trace efforts must meet their needs. He describes their investigations and solutions as they take a lead in improving and upgrading traceability of pharma products from manufacturing to end user.

The Pharma and BioPharma sector is very important in the Irish industrial scene. There are nearly 25000 people in this sector alone, no small figure in a state with a population of around 4.3 million. This was recognised in the two Pharmatex Conferences in which Read-out had a part in organising from the automation point of view. In 2007 an extrememly successful day long seminar on “Wireless in the Pharma Industry” and in 2008, a half day seminar on “Industrial Communications”.