Bahnson Environmental Specialties Walk-In Freezers

Walk-in chambers sometimes hold billions of dollars worth of product, which is why we use an innovative three-tier system to ensure our chambers remain fully operational in the event of an emergency.

Bahnson Environmental Specialties low-temperature walk-in freezer installation team has gone nearly two decades without a product loss event — a testament to our leadership in large-scale, ultra-low freezer design and construction.

For more than 50 years, Bahnson has been designing and building custom environmental chambers.

Instead of forcing you to design around existing chambers, Bahnson offers specialty solutions that fit your unique needs and applications.

We are excited to share the news that Bahnson Environmental recently completed the installation, start-up, and validation of their 129th large-volume, -70C environmental chamber. For 21 years, they have provided the pharmaceutical industry reliable, ultra-low temperature storage, successfully protecting billions of dollars worth of production value.

Bahnson’s Specialty designs and builds offer fast temperature recovery, with the utilization of pass-thru chambers, to provide a safe, controlled environment for moving materials between clean rooms and in and out of storage. A variety of custom design options are available.

For more information or to receive a quote, please contact our corporate office at: 800-829-5741

Tequila Seminar & Tasting Event: A Night of Connectivity & Learning

Mingle with Mesa at the Riverwalk!

Here’s what you can expect at this event: 

  • Tasting a rare Texas-only tequila called Double Barrel Reposado
  • Learning on, creating and sampling unique margaritas with different tequilas
  • Eating popular, local small plates – perfectly paired with each tequila type   

Also, we will feature a 15-minute presentation by an industry expert on ways to reduce product loss through continuous monitoring.

RSVP now to secure your spot! https://info.mesalabs.com/tequilaseminar

Event Location & Time:

Sunday, October 20th

6:30pm – 9:00pm

Agave Room at the Iron Cactus

Bonfiglioli Engineering Inspection Post

As you already know by now, the B.E.Inspection Post (quarterly journal by BONFIGLIOLI ENGINEERING), contains a wide range of topics like technology insights, what’s happening inside B.E., interviews with team members, contributions by our stakeholders, book suggestions, upcoming events, case studies and lots more. It is the people’s magazine and the articles have been written by diverse team members of Bonfiglioli Engineering.

In the third edition, we focus on Lean Manufacturing and how Bonfiglioli engineering has embraced this concept for optimal processes and results, an insight into our Product Sheets, an article on the History of Aerosols, the new website and an interview with our colleague in the company.

The B.E.Inspection Post represents our company and each one of us. This is our way of being closer to you, our Clients, Employees, Partners, Suppliers and sharing a part of ourselves with you.

We sincerely hope you enjoy reading it.

Do send us your feedback.

Click on the cover to get your copy NOW!

Turn-key integrated solution Case Study

Case Study: when one of the biggest European tuna can producers was losing cans to uneven heat distribution in processing, Fedegari developed a turn-key integrated solution that resulted in 0 rejected cans.

The challenge

Overcoming undesirable temperature fluctuations and overheating, guaranteeing homogeneous heat distribution throughout the load. · Developing a fully integrated solution for treating different tuna can formats, increasing productivity and, consequently, reducing operating costs.

The context

The nutritional quality of the products as well as microbiological and sensory quality are essential factors in the food industry. The thermal processing of canned food is the most important step in the canning procedure1 . Currently, a large quantity of canned goods is rejected during production and has to be destroyed or reprocessed due to inefficient performances of sterilization. This increases the energy consumption and other significant food processing costs. 1 Ibrahim M. Ismail, Alaa Fahmy, Ahmed Azab, Magdy Abadir, and Seif-Eddeen K. Fateen. “Optimizing the sterilization process of canned food using temperature distribution studies”IOSR Journal of Agriculture and Veterinary Science (IOSR-JAVS). For example, overcooking may cause a weight reduction of the product which obligates the manufacturer to complete the cans with additional product in order to comply with the weight indicated on the labelling. Such practices are costly. Sterilization plays a vital role in the food industry as the final product is intended for human consumption. It also represents a critical process since it may influence the quality and safety of the food. In this context, only optimal processing conditions through the proper application of the F-value approach in sterilization allows to optimize the balance between food safety and quality requirements. It assures an appropriate and homogeneous thermal treatment, thus avoiding over- or undercooking, and consequently maintaining the highest standards for uniformity of texture, flavor, and retention of nutrients.

The solution

Process knowledge applied in the development of a fully integrated solution for food preservation and throughput maximization. Fedegari superheated water sterilizers – FOW series (Fig.1) were chosen for improving process performance and throughput. The choice focused on the simplest, most robust and cost-effective solution for sterilizing at a wide range of temperatures with the shortest process time. Fedegari designed an unique, but completely integrated and accurate system. The key for an outstanding performance is the effective control of temperature and F-value which guarantees the highest uniformity to the sterilization process. Control efficiency eliminates errors and rejected loads while operating cost-effectively. The goal was to guarantee the microbiological target along with thermometric performance, through a new process design capable of offering competitive advantage over conventional alternatives. Besides, an additional concern was raised regarding the packaging quality.

The results

Fedegari has supported the customer, one of the biggest European tuna can producers, with in-depth knowledge in sterilization processes, developing a turn-key integrated solution focused on throughput maximization. The customer has increased its productivity at the end of every cycle and the number of rejected cans has been reduced to zero.

FVA/A1 – VERTICAL LAB STERILIZER

The FVA/A1 Vertical Lab Sterilizer combines design with Excellent performances and simplicity of use.

The automatic vertical sterilizer FVA/A1 has been specifically designed and developed to meet the most demanding application requirements in many different sectors, from universities to quality control laboratories in pharma, food or cosmetics industrial sectors.

FVA/A1 autoclave is the perfect solution for highly specialized fields and challenging customers worldwide that demand exclusive, reproducible and validated processes. These sterilizers have been designed with ergonomic features for easy handling and daily use.

The basic version of FVA/A1 can be used for standard processes and is easy to configure, thanks to its conceptual design and modular construction with exclusive optional kits. Please, click on the link “recommended kit” to check out all possible configurations referred to FVA/A1 series.

DESIGN & TECHNICAL FEATURES

FVA/A1 autoclaves are available with three different chamber volumes: 75 liters (FVA2/A1), 140 liters (FVA3/A1) and 188 liters (FVA3/A1 Plus).

FVA/A1 lab sterilizers are equipped with AISI 316L stainless steel chamber and lid with automatic independent operation and control. The access to the technical area is assured by a wide front door with a special safety lock for easy maintenance.

The exclusive horizontal swiveling lid has a patented seal with a compressed air system for perfect airtight, safety and easy maintenance.

An internal heat exchanger, made of AISI 316L stainless steel and a fan for the rapid cooling system can be integrated in the lid. An internal heat exchanger, made of AISI 316L stainless steel and a fan for rapid cooling system can be integrated in the lid. The DCS Plus 10 process controller allows fully programmability: 30 cycles easy to customize in a multi-user environment and an interface for remote monitoring via Ethernet protocol.

The DCS Plus 10 process controller allows fully programmability: 30 cycles easy to customize in a multi-user environment and an interface for remote monitoring via Ethernet protocol. The operating software is fully validated and documented.

KEY BENEFITS

  • Satisfies the most rigid requirements of safety and quality according to international standards.
  • New materials providing chemical inert insulation and both thermal and acoustic: smoother, quieter and safer operations.
  • Energy-saving system.
  • Functional and attractive design.
  • High level of programming and control versatility.
  • Innovative and unique modular design.
  • Ideal positioning of operator panel and printer.
  • Optimized loading height from floor.

Want to know more about our sterilizer product selection, please give us a call and we’ll schedule an introductory conference.

Check out Mesa’s new website – features for improved navigation

Mesa is pleased to announce the launch of their newly redesigned website: mesalabs.com 

The goal of the new website is to provide better overall functionality and a more user-friendly experience. In addition, they’ve centralized most of the existing secondary websites (subdomains) over to mesalabs.com. This will give you more clear and direct access for navigating Mesa’s site better.

The launch of the new website includes the following new additions:

Products and services: Access these in the What We Do tab at the top menu bar or by using our search filter feature located at the upper left of each page. 

Technical resources and documents: Find these at the Documentation tab in the top menu bar. There is a new filtering feature, which allows for easier accessibility.

Documentation includes:

  • User Manuals and Instructions
  • Warranty and Services Information
  • Certification
  • Certificates of Analysis
  • Certificates of Conformity
  • Safety Data Sheets
  • Forms (Orders, Returning Goods, etc.)
  • and more…

In case you need to talk with Mesa, contact technical support or find a distributor, this is accessible at the top of the site from the menu bar under “Contact”. 

We’re confident the new site will enhance your experience with Mesa and be a valuable resource as it continues to evolve.

As always, if you need to contact our reps for any torque inquiries, do not hesitate to connect with us.

The Newman CTE350 Labelling Machine

A fully automatic labelling system which applies self-adhesive tamper-evident labels (security labels) to erected cartons.

The CTE350 is a fully automatic labelling system which applies self-adhesive tamper-evident and hologram labels (security labels) to erected cartons. Designed primarily for the pharmaceutical industry where line space is at a premium, the compact design permits easy integration into existing packing lines.

The CTE350 incorporates full Newman ‘validation-friendly’ specification.

At the infeed, cartons are separated, held under a top belt and transported past two stepper motor-driven label stations. Labels are dispensed on to the overhanging vertical faces of the carton and applied with a roller.

Airplane and reverse tuck formats can be accommodated. Cartons proceed to the sensing station where sensors detect label presence prior to wipe down. 

Both labels must be present for a carton to be accepted; if not, it is ejected into a secure reject area.

Features

  • Compact
  • GMP Design
  • Stainless steel finish
  • In Process Control
  • Stepper motor drive for label web
  • “Positive accept” security system
  • Automatic critical device checking
  • Reject verification
  • Product and reject counter package
  • All adjustments scaled for repeatability
  • No change parts
  • Validation Documentation Package

For more information and pricing please contact us 800-829-5741.

Bahnson’s ES2000 Reach-In product line

The ES2000 reach-in stability chambers is provided in four standard sizes, ranging from 12 to 144 cubic feet, each offering a wide variety of temperature, humidity, and light (photostability) capabilities.

Our typical reach-in chamber uses include ICH stability, shelf life studies, photostability (ICH Q1B Option 1 and 2), incubators, plant growth, tissue culture storage, freeze-thaw, blast freezing, and other product testing and/or stability storage.

Chambers can also be designed to meet classified storage requirements (Class 1 Div 2), HEPA filtered cleanroom standards (Class 100-10,000), cycling/stress test requirements, or other special design requirements on request.

BES offers a range of environmental test and stability chambers designed for high demand testing, processing, conditioning, or growth applications.

The ES2000 product line includes six standard models. Standard temperature capabilities range from 2° C to 70° C, with controlled humidification, lighting and CO2 available.

We can provide complete performance qualifications on our and competitive chambers. Our staff writes your IQ, OQ, and PQ Protocols and trained technicians perform field tests and validation qualification tests.

Calibrations and test equipment used during qualifications are NIST traceable and are provided as part of your validation services.

Comprehensive reports are written to summarize your data for quick reference by your company and for regulatory agencies.

Please contact a member of our sales department for more details on how we can accommodate your testing needs.

Contact our product specialists to acquire further information.

FOW – SUPERHEATED WATER STERILIZER

FOW water cascade sterilizers are able to perform counterpressure sterilization through superheated water.

In compliance with cGMP and FDA standards for LVP products, FOW autoclaves are suitable for treating loads in containers that may be deformed due to the difference in pressure between the chamber and the container itself.

Where the product is liable to separation or for accelerating thermal transition phases, the whole load can be rotated during the entire sterilization process.

  • Process optimization: The process is faster than the air-steam sterilization process. FOW is also an ideal sterilizer for <105 °C processing.

Wet loads can be overcome using an automated drying extension with the installation of specific drying solutions downstream of the sterilization chamber.

  • Easy validation & integrationThema4 process controller is pre-validated according to GAMP5 and in compliance with 21 CFR Part 11, thus resulting in shortest qualification time and minimizing project risks. An open system architecture that can be integrated with SCADA system and other Fedegari machines.
  • Highest productivity: Fedegari R&D laboratory is available to develop the best treatment solution for your specific needs. We run tests with different loads and requirements.

TECHNICAL FEATURES

  • FOW superheated water sterilizer is equipped with AISI 316Ti (AISI 316L upon request) stainless steel chamber.
  • Besides the standard versions from 830 to 14.800 liters, the loading capacity is fully customizable according to customer needs.
  • Chamber internal surface electropolished with a roughness Ra <0,4 μm.
  • One or two doors with vertical or hinged opening systems to cope with available space in the smartest possible way.
  • 5 RTD PT100 probes for temperature control (2 fixed – in the filter and discharge – and 3 flexible for the load).
  • Automatic sterilization of the air filter with a fixed RTD PT100 temperature probe.
  • 2 validation ports.
  • Fedegari exclusive patented door gaskets assure 100% tightness.
  • Piping and valves in AISI 316L stainless steel.

APPLICATION FIELDS

  • Sterilization of parenteral solutions, liquids in sealed containers not deformable (eg. glass vials) and liquids in heat-sensitive sealed containers (eg. plastic bags or bottles).
  • Terminal sterilization of prefilled syringes (PFS).

SPECIAL APPLICATIONS

ROTATING LOAD

The load is held in rotation thanks to a special rotating drum inside the chamber. The rotation drum has a magnetic coupling and is adjustable in speed, the direction of rotation and intermittently. This system finds application in the treatment of suspensions and emulsions and ensures better performance of the tightness tests for ampoules under vacuum and more homogeneous heat transmission in the load.

VIDEO

COMPLIANT TO

  • ISO Standard: 9001:2015, 13485:2016
  • European directives: 2014/68/EU – Pressure Equipment Device (PED), 2006/42/EC – Safety of machinery, 2014/30/EU – Electromagnetic compatibility, 2014/35/EU – Low-voltage device, 2007/47/EC – Medical device
  • European standard: EN ISO 12100, EN ISO 13857, EN ISO 13849-1 EN 55001, EN 61000-4-2, EN 61000-4-4, EN 61000-6-2, EN 61000-6-4, EN 60204-1
  • ASME: Stamp R, Stamp S, Stamp U
  • FDA
  • GMP

Want to know more about our certifications? Please visit the dedicated section or do not hesitate to contact us.

Filling and Packaging Line for Flavoring

Recently, Cozzoli was approached by this customer who was looking to fill gallon-sized containers of liquid flavoring. This was to be a complete line that would incorporate filling, capping, labeling and case packing. Because of the high alcohol content of what was being filled, the filling and capping sections needed to also be explosion-proof.

With the required speed of 20 containers per minute and the containers being clear, it was decided that a 10-head In-Line Fill-To-Level and our Versacapper were the best machines for this application. By using a fill-to-level machine, the liquid in each container would appear to be visually identical. If a volumetric filler was used instead, the volume of each container would be accurate, but due to slight variations in the containers, the visual levels of the liquid could appear higher or lower.

After being capped, the containers would then be moved to another room, via conveyor, where they will be labeled and eventually packed into boxes.

For the labeling and case packing sections of this line, we reached out to our partners at ID Technology and EpsonThe challenge for these areas was that the customer wanted the labels to be print-on-demand. Rather than having the labels feed off of a role, which is the typical application, they needed to be fed directly from the printer to the labeler.

The biggest challenge of integrating the printer with the labeler is that the printer backs up about 12” every time it begins to print. To combat this issue, we used a loose-loop system that uses sensors to monitor the status of the printer and labels.

3 sensors were added into the loose-loop system. The lowest sensor monitors the loose loop to stop the printer when enough labels have been printed.  The middle sensor tells the printer to produce more labels.  The top sensor signals out-of-labels and stops the applicator until more are available. By using this loose-loop system we successfully integrated the printer with the labeler.

Finally, after labeling, the containers are then moved to a table where they are manually packed into boxes and fed through a case packer, which automatically closes, tapes and applies a label to the box.

For more information on how we can help with your complete filling line applications, contact our offices at 800-829-5741

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