Handling glass syringes, cartridges and vials are a key step in the ‘fill-finish’ process used by the pharmaceutical industry. The glass is commonly referred to as a ‘primary pack/container’ which refers specifically to the packaging containing the drug in either a liquid or powder format. Glass primary packs are normally delivered to side in a small package of up to 100-200 items, these are either manually or robotically unpacked before being places into an infeed system. Infeed systems have a significant range of designs, from conveyor belts to vibration plates at an angle, coupled to a system aimed at singulating each primary pack for handling on a manufacturing line; these vary from simple funnels to infeed scrolls. Glass breakage is a well-known issue in glass primary pack handling processes, and it a costly issue due to the danger involved in filling primary pack systems with drugs that will be typically be injected into the human body. Glass primary packs are known to be at risk of reduced strength due to micro cracks in the glass. Suppliers of glass primary packs as well as pharmaceutical fill-finish processes face significant issues in speed of handling versus cost of manufacturing operations, and hence different grades/strength of glass are available in order to compensate for this. In the current work, a Discrete Element Modelling (DEM) approach was used to demonstrate the capacity of an infeed conveyor coupled to an infeed pickup scroll, with respect to moving thousands of glass primary packs from a bulk mass on a conveyor table into a singulated conveying line. Some of the challenges that occur in these scenarios are that the bulk mass of glass primary packs begins to behave as a quasi-fluid, and the DEM model was able to reliably reproduce this phenomena. The bulk structure takes on a semi-crystalline structure, with fracture planes slowly forming and disappearing again, similar again to typical observed behaviours. The key element of the DEM modelling was to capture the residence time of any given glass primary pack, as it is postulated that the longer the primary pack remains in the bulk mass recirculating, the more small collisions it will experience, and in-turn there is an increased propensity of potential microcracks. It is therefore preferable to minimise the time spent on the conveying tables, and so DEM was used to explore the mechanisms and ideate around potential solutions that could reduce recirculation times for scroll infeeds. Multiple conveying table geometries were trialled using DEM in order to assess their ability to reduce the bulk recirculation, and outputs from the modelling used to determine the efficacy of the new geometries for reduced residence time. The outputs released additional insight into the typical movements of the glass in and around the infeed scroll, and they demonstrated that there is potential to reduce bulk recirculation and residence times using said geometries.
Reference | NWC23-0346-extendedabstract |
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Authors | Harley. P |
Language | English |
Type | Extended Abstract |
Date | 17th May 2023 |
Organisation | Crux Product Design |
Region | Global |
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