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High Containment Solution Prep

For this project, Rheo designed and fabricated an integrated system for transferring a variety of highly potent materials into process vessels through a high shear mixer. This turn-key system featured a Material Transfer Station, a Vacuum Conveyance System, a custom Hopper Skid, an inline IKA Disperser, and an integrated control system.

The Material Transfer Station, with the rigid isolator, is an easy to use workstation with integrated weighing and a sophisticated controls package that allows for safe and efficient solids transfer into a process vessel. The system allows for multiple drum transfers while keeping operator exposure levels less than 1 µg/m³ and oxygen levels below 1% for the duration of the process.

The Vacuum Conveyance System creates a closed transfer system between the Material Transfer Station and the custom hopper so that material can be safely transferred while maintaining containment levels below 1 µg/m³.

The custom Hopper Skid holds the material as it is fed into the high shear mixer. The top of the hopper is complete with a breather filter, sight glass, level sensor, and CIP spray ball. The hopper discharge includes the required valves and connections to ensure the proper feed-rate for the high shear mixer.

The IKA Disperser is an inline high shear mixer that disperses product from the hopper into the liquid stream as it recirculates through the process vessel until the desired solution blend is achieved.

This entire process skid is managed using the latest hazardous rated instrumentation with ethernet over IP connectivity and a graphic based HMI. The PID controlled logic enables optimized operational sequencing while minimizing operator input, allowing for increased productivity and process control.

Key Equipment

Material Transfer Station

The Rheo Material Transfer Station (MTS) offers cutting edge technology to allow fast and contained transfer of powders into process equipment. This state of the art workstation brings operator ease to the challenging transfer process while increasing the level of safety and process control. The MTS can be used with many drum charging applications to improve operator safety, protect product quality, and increase production efficiency.

Rheo - Containment Equipment - Material Transfer Station

Vacuum Conveyance System

The Rheo Vacuum Conveyance System [VCS] provides a safe, efficient, and contained means for transferring material using a vacuum source instead of relying on gravity. The VCS is ideal for transferring highly toxic or potentially explosive powders that are present in the pharmaceutical, food, and chemical industries. Safety, containment, and productivity are all addressed with this simple to use machine.

Powder Disperser

The integrated powder induction system allows for unloading into a disperser system that can mix the product with a solution and pump it directly to, or recirculate through, the receiving vessel. Minimal dry cleaning areas improve the mix times for transferring to liquid vessels.

Bulk Bag Unloading Station - Powder Induction System

System Performance: OEE

  • Powder Transfer Rate: 1800 kg/hr
  • Up to 5 drums transferred per hour
  • Oxygen Concentration down to 2%
  • Containment: less than 0.5 µg/m3
  • Fully Closed Transfer Process
  • Validated CIP Cleaning of Vacuum Conveyance System

High Potency Solids Addition for Spray Dryer Solution Prep equipment Rendering