From pre-industrialisation to mass production
When developing a new process, it is sometimes necessary to go through the pre-industrial stage to allow chemists and pharmacists to refine their process before launching the construction of new production plants.
AGITEC is able to design and manufacture this type of stirrer which will allow the industrialist to extrapolate when scaling up.
The gantry-mounted stirrers shown here is equipped with a tank, a manual lifting and lowering system and an stirrer mounted on slides that allow the tank to be fully opened. This flexible solution has been designed to help users adjust and refine their processes. Quick-pin connectors on the side of the gallows allow the installation to be connected to the skid's global control system.
This particular project will move to industrial scale in 2024.
THE IMPORTANCE OF AGITATORS IN THE PHARMACEUTICAL AND CHEMICAL INDUSTRIES
The production of chemical and pharmaceutical products has evolved from their preparation in small artisanal laboratories. Mass production is now necessary to meet a strategic and growing global need. In research centres, the development of a new process often requires going through a pre-industrial stage. Chemists and pharmacists refine their processes before launching the construction of new production plants equipped with the latest generation of full-scale agitators.
PRODUCTION STAGES IN INDUSTRY
At the pre-industrial stage, the agitators play an important role in the design of the equipment, which is adapted to the various trials and tests. This intermediate stage, the heart of the process, fine-tunes the vision of the future industrial chain. When the mass production tool is launched, the equipment, adapted to the impressive dimensions of factories 4.0, is immediately functional and efficient without the need for adjustment and fine-tuning phases.
FROM SMALL-SCALE MANUFACTURING TO MASS PRODUCTION
The use of agitators in the manufacturing process has contributed to the development of both pre-industrial and mass production techniques in the pharmaceutical and chemical industries. Modern agitators are designed to meet high-volume requirements, enabling products to be manufactured in large quantities. Efficient mixing, emulsifying and dissolving processes are then accelerated. This reduces production time and increases the output of the production line.
THE BENEFITS OF MASS PRODUCTION
Once the pre-industrial stage is over, mass production offers a number of advantages for manufacturers. It makes it possible to respond effectively to the growing demand for pharmaceutical and chemical products. Large-scale production guarantees a constant supply to world markets throughout the year. Mass production also optimises manufacturing costs. This often results in more affordable products for patients and users.
THE IMPORTANCE OF SHAKER MANUFACTURERS IN INDUSTRIAL MANUFACTURING
The professionalisation of agitator manufacturers has contributed to a major advance for the pharmaceutical and chemical industries. Today, this solid support from specialists enables manufacturers to base their process dimensioning with confidence, thanks to well-founded approaches. Agitators (mechanical devices) enable the active ingredients and excipients needed to produce different mixtures to be mixed efficiently. Agitators ensure a balanced distribution of substances in the solution, which improves the quality and stability of the final products.
CHALLENGES AND TECHNOLOGICAL ADVANCES
The transition from pre-industrialisation to mass production presents a number of challenges. Scale management, heat exchange stability, possible sterilisation constraints, cleanability and safety are all areas that require technological advances to guarantee the quality and conformity of mixed products.
The materials used in the manufacture of the equipment in contact with the preparations are also studied to meet the requirements in terms of the lifespan of the installations. Agitation techniques have also evolved to preserve the integrity of the products manufactured.
EQUIPMENT AND AGITATORS FOR THE PHARMACEUTICAL AND CHEMICAL SECTORS
AGITEC offers equipment to meet the different needs of the industrial process. Pre-industrialisation stirrers are designed to meet process requirements and operating conditions.
For specialised processes (cell cultures, chemical reactions, etc.), a tank top stirrer or tank bottom stirrer is the preferred choice. Lateral stirrers will be selected for buffer tanks (storage between phases or before packaging, maturation, etc.)..
Simple continuous mixing will be handled by static mixers installed directly on the piping lines. AGITEC is able to design and manufacture a wide range of mixers that will enable manufacturers to scale up their processes.
For example, to meet a specific need, a jib crane fitted with a tank, a manual raising/lowering system and an agitator mounted on slides allowing the tank to be opened completely has been designed. This flexible solution helps users to adjust and refine their processes. Quick-pin connectors on the side of the bracket connect the installation to the skid's global management PLC. This particular project will move on to industrial-scale production in 2024.