Is it possible to perform a pilot plant upgrade quickly and fully tailored to your needs?
Our team of experts in flexible containment recently completed a pilot plant upgrade in Spain, working closely with the client throughout the entire process. Flexible containment technologies make it possible to achieve results that would otherwise require extensive facility revamping—significantly reducing both time and cost.
Containing Costs and Workspaces.
From the initial site inspection to final installation, only a few months passed. In that time, we transformed a standard work area into a confined and clean environment, where operators can work safely while following GMP practices.
The client, for its HPAPI Pharma site, needed to contain a filter dryer, considering both the cleaning operations and the replacement of filters. In addition, an entire area had to be confined due to the handling of highly potent compounds. This represented a significant shift for a department that, until then, had not required this level of protection and safety.
A Safe Change.
One of the main challenges of this project was to contain the filter change operation of a dryer unit. The filter was positioned at a considerable height, requiring a custom isolator that would ensure both ergonomics and operator safety during use.
The solution included a raised steel platform designed to integrate all process piping. The isolator was secured to this structure using a profile and U-grip system-ensuring a safe, tight, and easily removable setup. Additional safety components included suction cups and elastic cords to anchor the isolator to the ceiling, integrated gloves, and bag-out canisters for safe filter removal.
But downstream of that, to secure the dryer cleaning phase, we provided another tailored isolator connected to the unit’s interface-spacious and ergonomic enough to allow complete cleaning movements from outside, eliminating any risk of contamination.
An added layer of safety is provided by a manual negative pressure regulation system, based on Venturi technology, manual valves, and interlocked safety systems connected to an external barrier protecting the gloves.
A Solution for Every Need.
Since customization is the hallmark of CSV Containment, even with well-established solutions, we design distinctive systems tailored to each client’s specific needs.
In addition to the main containment systems, the client required two further installations: a dispensing isolator and the setup of a cleanroom. Once again, flexible containment technology made both possible.
While for the dispensing isolator, we supplied one of the most requested and reliable models from our range, the real challenge came with the cleanroom, intended for both material and personnel entry. The goal was to install it in the shortest possible time, while ensuring full integration with the existing facility.
Operators were immediately struck by the transparency and brightness of the installation, made from polyurethane and steel. This lightweight yet robust structure drastically improved operations without heavily impacting the surrounding workspace.
A sealed tunnel now leads just from the entrance directly to the flexible cleanroom. Equipped with flexible PAL-MAL (Personnel Airlock – Material Airlock) systems, they allow controlled access and ensure clean and safe transfer of both personnel and materials into the controlled area.
Combining Expertise.
By merging expertise in flexible technology with in-house capability to design and manufacture stainless steel structures, our workshops and Flexilab can deliver environments that come very close to rigid-wall installations. This offers an ideal compromise for temporary or long-term upgrades, like the one described.
Inside the rooms, positive pressure cascades maintain safe separation between areas, and an emergency shower is also integrated and ready for immediate use when needed.
Planning a Pilot Plant Upgrade?
Consider a flexible containment solution. We’ll work alongside you to develop safer and more efficient production processes-tailored precisely to your needs.
CSV Containment provides tailor-made solutions for pharmaceutical and fine chemical sectors in terms of containment. For more info: containment@csv-ls.com
