Batch Controls : Pharmaceutical and Food Industries Fuel Growth

Dedham, MA -- The food and beverage industry is showing the largest growth for batch control systems. This industry sector, which still depends on manual operations, is relying increasingly on automation to improve productivity and product quality. That is being closely followed by the pharmaceutical industry. With the approval of electronic batch records and signatures by the FDA in the US, there is now greater incentive for the regulated industries to move to paperless systems.

The worldwide market for batch process control is expected to grow at a Compounded Annual Growth Rate (CAGR) of nearly 6 percent over the next five years. The market, $2,800 million in 2004, is forecasted to be over $3,700 million in 2009, according to a new ARC Advisory Group study, Batch Control System Worldwide Outlook. “The rise of the Asian economies is increasing the demand for packaged foods and beverages, which is leading the demand for batch control in that region,” according to ARC Vice President Asish Ghosh, study’s principal author.

Services Will Dominate the Batch Control Market

Services constitute the largest part of a batch control system, which include integration and maintenance services provided by control system suppliers, and third party services provided by system integrators and other independent agents. Integration services provided by suppliers will show the largest growth, closely followed by third party services.

FDA’s PAT Initiative Will Fuel Growth in Pharmaceutical and Biotech Industries
The Process Analytical Technology (PAT) initiative underway within the FDA aims to encourage the concepts of quality by design, use of computerized data gathering and evaluation techniques, and process and product monitoring methods through advanced instrumentation and data evaluation. ARC feels that the PAT initiative is going to have a significant effect on drug manufacturing and the validation process. It will lead to the storage and analysis of a much larger amount of batch data than what is required today. Accurate time stamping and the security of the stored data will become increasingly important along with their automated analysis. Optimization of current and future lots based on the analysis of these data will also become increasingly important.

Asian Market Will Provide Impetus to Growth

The manufacturing industry in Asia has entered a rapid growth phase with China in the lead. The people of Asia, with changing demographics and lifestyles, are creating a massive demand for life science products. In response, the food, beverage, and pharmaceutical industries are growing. Many countries such as China, India, and Singapore in the region are focusing on setting up pharmaceutical facilities to produce bulk drugs and generics.

For more information, please visit our Studies Section.

Founded in 1986, ARC Advisory Group has grown to become the Thought Leader in Manufacturing and Supply Chain solutions. No matter how complex your business issues, our analysts have the expert industry knowledge and first-hand experience to help you find the best answer. We focus on simple yet critical goals: improving your return on assets, operational performance, total cost of ownership, project time-to-benefit, and share holder value.

Further information can be obtained from:
ARC
Three Allied Drive
Dedham, MA 02026
Telephone: 781-471-1000
Fax: 781-471-1100
Email: info@arcweb.com
Web site: http://www.arcweb.com/

Pharma Feeder : Engineered for Tablet Press Lubrication

PITMAN, NJ -- The K-Tron Feeder Group now offers the K-Tron Tablet Press Lubricant Feeder. An adaptation of K-Tron’s sanitary pharmaceutical design twin-screw feeder, the tablet press lubricant feeder features the addition of a specialized gas venturi for aspiration of the lubricant (such as magnesium stearate) directly to the tablet press. The Tablet Press feeder is available in both volumetric and gravimetric (loss-in-weight) models and can be offered on a portable cart.

Precise control of the amount of lubricant used in tablet press applications is essential in order to reduce the compression force during tabletting, to avoid product buildup on the tablet press tools, to make the tablet surface smooth and assure overall product quality. If too much lubricant is added the tablet can often become softer than required. This becomes critical in the production of effervescent tablets, where excessive magnesium stearate can actually cause the tablet to repel water, thus affecting the dissolution into water.

Using the K-Tron Tablet Press Feeder outfitted with a specialized gas venturi for aspiration of the lubricant directly to the tablet press tools, rather than adding the lubricant to the mixer, can drastically reduce consumption of the lubricant, sometimes by as much as 97%.

The K-Tron Tablet Press Feeder offers an automated, nearly constant feed rate, offering uniform coating of the tablet tools and avoiding sticking problems. The benefits of its use include reduction in the consumption of stearate, lowering material and operating costs, and improved product quality. Use of the gravimetric (loss-in-weight) model enables validation of product mass flow and ensures higher accuracy.

For more information, contact:
K-Tron Feeder Group
Routes 55 and 553
Pitman, NJ 08071
Phone 856-589-0500
Fax +1 856-582-3937
Email to info@ktron.com
Web site: http://www.ktron.com

Food : Processors Maximize Quality with Sorters

Walla Walla, WA -- Key Technology’s Optyx® G6 3000 Series Sorter automatically detects and removes defects and foreign materials from the product stream, improving product quality and optimizing food safety while reducing labor costs. When located immediately upstream of the packaging operation, the new Optyx G6 assures processors and their customers that packaged products meet specifications.

With Key’s high intensity discharge (HID) illumination system and G6 CCD-based camera technology, Optyx analyzes size and shape as well as millions of subtle color differences. Optional Vis/IR technology maximizes the recognition and removal of protein-based animal matter such as grasshoppers and moths, even when their color is identical to the product stream. Optyx G6 can also be equipped with Key’s new Raptor Laser Technology to maximize the removal of foreign material based on differences in the optical properties of the material. As the only Class I laser sorter in the food industry, Key’s Optyx G6 Sorter with Raptor Laser Technology sets a new standard in inspection performance and safety.

Optyx G6 3000 is ideal for fresh-cut food processors handling up to two tons of product per hour. With superior detection of defects and foreign material, Optyx eliminates costly hand-sorting labor and offers rapid payback.

The Optyx G6 3000 Series Sorter features a 24-inch wide scan width and up to three sensors located above and/or below the product stream, depending on the application. As product passes through the sorter, it is launched off the end of the Optyx belt for in-air viewing by the sensors. Using Key’s proprietary image processing technology, the sorter quickly analyses the images, comparing each object to previously defined accept/reject standards.

When defective product or foreign material is identified, the system activates the close-coupled high-speed ejector system, which is made up of a series of air jets spaced 6 mm apart that span the width of the system. While the defective object is still air-borne, the air jets pinpoint the object to reject and remove it from the acceptable product stream. The Optyx infeed belt moves at a rate of 3 meters per second and the sorter achieves 4000 scans per second.

The compact, self-contained unit slips easily into the processing line – connect to air, power, and water, and start sorting. Optyx features a flat belt with air-tensioning for consistent tracking and minimal maintenance. The quick-release feature and easy-access cantilever design make belt replacement fast and simple.

For more information contact:
Key Technology, Inc.
150 Avery St.
Walla Walla, WA 99362
Phone: 509-529-2161
Fax: 509-527-1331
http://www.key.net/

Paducah, KY -- PEBCO offers a variety of diverter gates to divert flow as well as split product flow. Our Single Blade Diverter, commonly know as a flop gate, is custom built to fit each individual application.

The unit features:
-Heavy-duty construction
-Abrasion-resistant steel blade
-Elastomer seals
-Various sizes, angles of diversion, actuation styles, and materials of construction.
-Outboard bearings

This unit is ideal for diverting gravity flow of materials when it is not critical to have complete sealing between legs or where cutting through a standing column of material is not required.

PEBCO is recognized worldwide as a manufacturer of powder and bulk solids equipment. Products produced range from truck, train, and shiploading equipment to gates, valves, diverters, mass flow feeders, Cascade® chutes, dustless loading spouts, and telescopic chutes. PEBCO acquired Cleveland Armstrong® in 1983 to complement its line of equipment. PEBCO’s capabilities range from application engineering, CAD design, manufacturing, start-up services, and a complete customer support program.

For further information, please contact:
Mr. Mark Kettler
Pebco, Inc.
Phone: 270-442-1996
Fax: 270-442-5214
Email: kettler@pebco.com
Web site: www.pebco.com

I

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New Gearmotor Meets Food Industry Requirements
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Cleanaway Teams Up with InBulk Technologies Cleanaway has acted quickly to the challenges of the new legislation by re-evaluating their processes for wastes that are directly affected.

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Mr. Strimenos wants long-wearing elbows:

My company uses a Modco dilute phase conveyor to move kiln alkali baghouse bypass dust. We've run into problems with abrasion at elbows. The dust causes a constant maintenance problem and I'm looking for a cost effective way of reducing maintenance.

Is there a lining that others have had success with or is there another solution that I haven't thought of yet?  (to post reply, click here)

Thanks,
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Holcim
ostrimenos@hotmail.com

Mr. Callinan wants dry calcium carbonate:

What is the best way to dry calcium carbonate powder from 0.5% weight moisture to 0.05% weight moisture ?

I also need it to be no greater than 40 degrees Celsius before being used in a downstream process. I am also aware that it needs to be sealed while it is stored otherwise it will take up moisture from the atmosphere.

We use 3,000 kg of powder per day. I would also like to extend the process to dry titanium dioxide powder as well. Is a vacuum dryer the best method ?
(to post reply, click here)

Thank you,
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Bostik Australia
tim.callinan@bostik.com

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