Contained reactor charging solutions for flexible, safe and efficient powder transfer.
Contained reactor charging is a critical operation whenever powders must be transferred while protecting operators, products and the surrounding environment. In pharmaceutical and chemical production, this process often has to be performed in complex layouts, with limited access to the reactor manway.
CSV Containment has developed a wide range of disposable flexible isolator solutions designed to support these operations with a high level of versatility. Through a series of videos, conceived almost as step-by-step tutorials, it is possible to see how different reactor charging configurations can be managed safely and efficiently in containment.
The purpose of this article is to present in video the main techniques currently available for contained reactor charging with disposable flexible isolators:
- secondary bag handling
- telescopic drum sleeve solutions
- isolators whit column lifter
- patented DIT technology with single or double iris
How can reactor charging be performed safely in containment?
Reactor charging can be challenging when operators need to combine containment, ergonomics and process efficiency. The reactor manway may be difficult to reach, the available space around the equipment may be limited, and the powder transfer operation may require different access points.
Disposable flexible isolators are particularly suitable for these conditions because they can be designed around the real geometry of the production area. CSV Containment can provide telescopic flexible isolators to better reach the reactor charging manway and create a contained connection exactly where the operation takes place.
The supporting structure can also be equipped with compass legs, allowing the station to be positioned as close as possible to the charging point. This helps operators work more comfortably, even when the reactor is installed in a restricted or difficult-to-access area.
Which powder charging options are available?
Different processes require different charging methods. For this reason, CSV Containment disposable flexible isolators can be configured with several options for powder transfer into the reactor.
In some applications, the operation can be performed using a secondary bag. This solution allows powders to be introduced into the isolator and transferred toward the reactor while maintaining a controlled workflow.
In other cases, the system can be equipped with a drum sleeve for drum-in operations. The drum sleeve allows the drum to interface with the isolator in a practical way, supporting contained powder transfer from the container into the reactor.
For more advanced drum-in applications, CSV Containment offers its patented DIT® technology. This solution has been developed to improve containment control, operator handling and speed during drum-in operations.
What is DIT® technology?
DIT technology is a patented CSV Containment solution for drum-in operations in containment. It can be configured with a single iris or a double iris, depending on the containment level required by the application.
The single iris configuration provides a practical and efficient interface for contained drum handling. The double iris configuration adds a further containment step, making it suitable for applications that require a higher level of control.
This technology stands out in containment by combining ease of operation, faster handling and effective containment control.
CSV Containment has installed DIT® technology on numerous rigid isolators over the years. This experience has provided a solid technical basis for transferring the same concept to disposable flexible isolators. The result is a flexible containment solution that combines the adaptability of disposable systems with the proven performance of DIT® technology.
From DIT technology to Disposable DIT®
The evolution of this charging technique is now leading to an important innovation: Disposable DIT®. 
The arrival of Disposable DIT® will further accelerate bag change operations. The entire isolator, including the DIT® system, can be collapsed as part of the disposable assembly. This development is designed to make end-of-use management faster and more practical.
To show how to collapse a CSV Containment flexible isolator safely, we have prepared a dedicated tutorial available on Vimeo. The video explains the correct sequence for managing the operation and highlights the design features that support safe closure and disposal.
For this type of operation, all parts of the isolator involved in an opening are manufactured with the necessary excess material. This applies, for example, to the reactor discharge sleeve, the canister sleeve and the drum-in sleeve. The additional material allows these areas to be closed safely using CSV Containment Twin Tie® systems.
This design approach supports containment not only during powder transfer, but also during the final handling and disposal phases.
What if there is limited space around the reactor?
Limited space is one of the most common challenges in contained reactor charging. Not every production room allows operators to work in ideal conditions. For this reason, CSV Containment offers different pneumatic lifting systems, including the traditional drum lifter and the pneumatic column lifter. Both solutions help operators charge reactors comfortably, adapting to space, layout and ergonomic requirements.
The solutions developed by CSV Containment are the result of continuous dialogue with customers and operators. Working directly with people who perform these operations every day is a valuable source of knowledge and improvement.
Every project helps identify new needs, refine existing technologies and develop systems that respond to real production challenges. For CSV Containment, this collaboration is not only part of the design process: it is a privilege and a driver of continuous innovation.
CSV Containment provides tailor-made solutions for pharmaceutical and fine chemical sectors in terms of containment. For more info: containment@csv-ls.com
