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Rinsing steps optimization in change of line process
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This master's thesis focused on optimizing the spray drying (SD) cleaning process in the pharmaceutical industry. This procedure is composed of four distinct cleaning phases, with this research specifically dedicated to the final two rinsing stages, where detergent is removed.
Over a 9-month period, 11 historical cleanings involving detergent use in the second cleaning phase were analyzed. The aim was to assess the viability of consolidating these two rinsing stages into one (merge) and to address the inefficiencies found.
Analyzing a past cleaning where a merge was attempted showed that the consistent need to refill the purified water tank made it unviable. So, the focus shifted partially to optimize the existing two-phase rinsing process where, not only the refilling time but also the existence of idle times and excessive flush executions were addressed.
As result, the study suggests integrating inline conductivity meters for continuous conductivity tracking and setting a minimum conductivity threshold for the initial rinsing. This measure eliminate needless flush activities and pave the way for a prospective automation recipe. Simulations performed showed potential cost reductions in rinsing phases by 15-21% with these automated recipes. The induction of an automatic purified water refill in the subsequent rinsing stage could cut expenses by an estimated 40%. By harmonizing this automatic refill with the batch recipe, potential savings might escalate to 42-60%. Nevertheless, due to the complexity of the automatic refill implementation, such an improvement should be considered a long-term project.
After implementing these suggestions, it's recommended to re-evaluate the viability of the merge. Additionally, assessing the sequence of zone executions and eliminating redundant cleaning zones can prevent unnecessary flush executions.
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Optimizing Cleaning Automation Batch Recipe Automatic Refill Merge