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Case Studies / Markets

Pharmaceutical Company Case Studies

Company Profile 1

Pharmaceutical company specializing in softgel technology in Highpoint, NC.

Challenge

Company wanted to transfer powdered material from multiple drums into a flexible IBC (ILC DoverPac) and then deliver the product into a mixer for processing. The entire process needed to be accomplished with high containment (1-10 micrograms).

Solution

IEDCO provided a custom drum handling system that lifted and tilted drums 90 degrees into a discharging position adjacent to the side of a custom isolator. The glove box isolator allowed an operator to access the inner liner of each drum and empty its contents into the flexible IBC on a scale system below. A custom frame, scale system, and transfer cart was created to hold the flexible IBC during the filling process and allow it to be removed and transported to the mixer for final discharging.

Benefits

This unique drum handling system allowed the customer to empty drums and fill flexible IBCs with extremely high containment and the utmost in operator safety.

Major Equipment Provided

Company Profile 2

International pharmaceutical developer and manufacturer in Petersburg, VA.

Challenge

Company needed to accurately batch powder from bulk bags into a reactor in one process, as well as have the ability to accurately fill bulk bags or drums with powdered product from dryers in another part of their facility. Both areas environmentally classified as Class I, Div II.

Solution

For the bulk bag unloading process, IEDCO provided a unique bulk bag unloader to be installed in the room above the reactor to be fed. The product was metered from the bulk bags via a sanitary rotary valve through a chute system in the floor. The bulk bag unloader had integrated load cells which allowed for creating accurate loss-in-weight batches to the reactor.

For the filling process, IEDCO provided four “zero lift” style pack-out units with individualized features and fill heads to allow for bulk bag filling or drum filling. The fill heads were also fit with a sieving system to refine the powder from the dryer. The pack-out units were designed to accept empty bulk bags or drums on pallets using a simple pallet jack – no forklift needed. Integrated with weigh modules, the pack-out units produced accurately weighed batches in either container.

All equipment supplied complied with the necessary specifications to operate in Class I, Div II environments.

Benefits

All the systems provided streamlined existing practices and increased overall process efficiency. By introducing the LIW bulk bag unloader above the reactor process, IEDCO eliminated the need for additional material transfer equipment. The pack-out units were designed for flexibility, ease of use, and safety. All systems offered complete contained transfers of the powdered materials, as well as accurately metered batches.

Major Equipment Provided

Company Profile 3

International pharmaceutical manufacturer in Mt. Vernon, IN.

Challenge

Company needed to discharge 20 liter poly-bottles containing either API or non-API powders into multiple mix tanks with inlets approximately 10’ above the floor. Material transfer needed to be ergonomically safe and contained (especially for the API powder solution).

Solution

IEDCO provided four pneumatic column lifts with custom designed lift effectors to handle the specialized poly-bottles. The lifts were able to lift, invert, slew, and dock the poly-bottles to the mix tanks. The API solution bottles and corresponding mix tank inlets were fit with split butterfly valves to ensure contained transfer of the active powder. The API bottles also needed to be rinsed with water and emptied back into the mix tank, again in a contained and safe manner. Lift controls were located on a pendant device, allowing a single operator to load the poly-bottles at ground level and then dock the bottles on a mezzanine adjacent to the mix tank inlet.

Benefits

The new poly-bottle lift and discharge systems allowed a single operator to discharge the powdered solutions in the 20 liter poly-bottles into the required mix tanks in a safe, ergonomic, and contained manner.

Major Equipment Provided

Food Processing Case Study

Company Profile 1

International food manufacturer in Jefferson, WI.

Challenge

Company was introducing three new LIW feeders into their condiment feeding line and needed a hygienic and accurate method of refilling each feeder with different products from a remote location without interfering with the scale system. The refilling area had limited headroom (<8’) as well as limited floor space. CIP was not possible, so the feeders and refill systems would need to be easily removed from the area for cleaning and maintenance.

Solution

IEDCO provided three new, large storage hoppers with integrated pneumatic feed wands in a nearby room which allowed bulk quantities of the products to be ready for feeding the new refill system. In order to satisfy the feeders refilling requirements while taking into consideration the height/space restrictions, IEDCO introduced a custom, low-profile pneumatic conveying system for each feeder. These specialized pneumatic conveying systems were also mounted on a mobile cart that would also hold the LIW feeders. Since the feeders had an open top and a contained transfer process was desired, custom covers were created that allowed the transfer of material from the pneumatic conveyors to the feeders in a closed system. A flexible connection was used to not interfere with the weighing process. Using a precise system of controls and level sensors, the feeder refilling process was now an accurate, automated, and contained system.

Benefits

The new IEDCO feeder refill systems eliminated long, manual refilling operations while increasing hygiene and efficiency with its closed and contained design. The portable cart design allowed for easy positioning of the feeders for processing, as well as simple removal for cleaning and maintenance.

Major Equipment Provided

Company Profile 2

Frozen meals food manufacturer in Jackson, OH.

Challenge

Company began receiving many ingredients (dried pastas and other food materials) in large Gaylord boxes and needed an efficient, low-manpower method of transferring the ingredients to their process without damaging the product.

Solution

IEDCO provided six Gaylord tilters with custom, pneumatically operated vacuum feed wand holders. These attachments moved the feed wand up and down during the vacuum cycle for maximum feeding efficiency and bridge breaker without the need of an operator. Six pneumatic conveyors were provided to transfer the materials from the Gaylords into the various process systems. Using dense phase conveying and a large flapper valve as the discharge feeder, we were able to transfer the different and delicate products without damage.

Benefits

The new IEDCO pneumatic conveying systems provided the necessary gentle product transfer without the need for multiple operators. The system was both efficient and cost effective.

Major Equipment Provided

Company Profile 3

Specialty nutritional foods manufacturer in Wautoma, WI.

Challenge

Company needed to dispense milk powder from bulk bags into a processing suite, but, due to the height of the processing equipment stack-up, the bulk bag discharging operation needed to be on the floor above and in a room with a standard ceiling height of 8’.

Solution

IEDCO provided a low-profile bulk bag unloader that discharged the bag’s contents through the floor and into the processing system on the floor below. A chute system was devised that could interface with the process system which featured an auger filler with varying operating heights. The IEDCO bulk bag unloading system featured a sanitary rotary valve that allowed for a controlled feed into the auger filler.

Benefits

The new IEDCO bulk bag unloader allowed the customer to discharge bulk bags in a controlled manner in an area with limited headroom in which no standard bulk bag unloader could fit. Utilizing the existing environment, the current processing stack-up did not need to be disturbed.

Major Equipment Provided

Chemical Industry Case Study

Company Profile 1

Polysilicon materials manufacturer for the solar industry in Moses Lake, WA.

Challenge

Company wanted to reclaim polysilicon powder captured by their existing dust collection system. Due to the vast size of the facility, the amount of reclaimable powder was considerable and would require 13 IBCs designed for Class I, Div II and Class II, Div II environments. Locations of the reclamation sites would be in three separate areas throughout the plant and at different altitudes. Due to the nature of the polysilicon product, a highly contained system was required. Eventually, the reclaimed product would need to be repackaged from IBCs into bulk bags for shipment elsewhere.

Solution

IEDCO provided the polysilicon powder reclamation system (IBC fill system) and the bulk bag filling system (FIBC fill system). The IBC fill system consisted of 13 IBCs, 10 Pneumatic Conveying and Batching Systems – all of which were designed for hazardous environments and high containment. Split butterfly valves were used to maintain the containment requirements. The portable IBCs were filled & emptied through the same valve and required both fluidization and nitrogen purging.

The FIBC fill system consisted of a Post Lift IBC Lift Inverter and a Bulk Bag Fill System that needed to fill bulk bags to an accurate weigh in a fully contained manner in a nitrogen purged environment.

In order to maneuver the IBCs throughout the facility, IEDCO also provided a Cable Hoist Elevator.

Benefits

Providing this complex system was a massive endeavor with equally impressive results. The new silicon powder reclamation system has created a new source of revenue for the company, as well as eliminated the need to dispose of what was once discarded material.

Major Equipment Provided

Company Profile 2

Industrial and reagent grade chemical manufacturer in Minneapolis, MN.

Challenge

Company needed to repackage an assortment of products received in bulk bags or paper sacks into a variety of different sized buckets and/or drums. They were looking for a linear system that would accomplish this in a contained, safe, efficient, and ergonomically friendly fashion.

Solution

IEDCO provided a complete material transfer and batching system consisting of 2 bag dump stations (with compactor), 2 bulk bag unloaders with surge hoppers, 4 vacuum tolerant sifters, and 4 pneumatic transfer batching systems. A portable delumper was also included to interface with either the bag dump or bulk bag unloader systems as some of the received materials become densified during transit in either bag type.

This linear transfer system was designed to keep operator’s feet on the ground while being able to access all aspects of the process. Product was discharged from either the bulk bag unloaders or the bag dump stations and fed through the vacuum tolerant sifter via the pneumatic conveyors in the next room. The pneumatic conveyors (mounted on pneumatic lifts to allow for docking & undocking with the containers) accurately filled a variety of different buckets and drums on a roller track scale system.

Benefits

This system allowed the company to create accurately batched containers of a variety of chemical ingredients for distribution from both bulk bags and paper sacks while increasing operator safety by keeping them on the floor at all times due to its linear design.

Major Equipment Provided

Company Profile 3

International specialty chemical manufacturer in Assonet, MA.

Challenge

Company was packaging their product in drums, but wanted the flexibility to also start packaging into pleated foil bags. The drum fill system was originally provided by IEDCO and allowed for the metered filling of drums on a scale system from an existing mixer.

Solution

Rather than introduce an entirely new packaging line, IEDCO retrofit the existing drum fill system with a new, custom designed foil bag fill head system that could utilize the existing floor scale and batch controller. The custom fill head featured specially designed bag gripping pads. Operator safety was a primary concern, so the gripping pads were designed to prevent operator fingers from accidental insertion into the pinch points. A foot pedal was incorporated to allow a single operator to use the system while maintaining control on the foil bag being filled.

Benefits

This system allowed the company to begin filling foil bags with their product without the major investment on equipment or a new filling line.

Major Equipment Provided