Heating chamber for pharmaceutical production at German Grenzach Production Company
A bespoke solution for heating waxes and petroleum jelly in the pharmaceutical sector was developed and implemented for a new German production facility at Grenzach Produktionsgesellschaft (GP), a subsidiary of the Bayer Group.
Challenge and task
The well-known ‘Bepanthen’ eye and nose ointment is manufactured at the site in Germany (Grenzach). The production capacity was to be expanded and modernised as part of a new building project. The requirements for facilities producing these medicines, which are administered internally, are very high – and for good reason. Furthermore, it must be possible to operate the facility in a practical manner within a pharmaceutical environment. As the raw materials required cannot be pumped or processed at room temperature, they must be melted down in drums within a heating chamber and brought up to the necessary processing temperature.
The Solution
DENIOS developed a heating chamber with four separate zones, three of which operate at a constant temperature (+/- 2 K). The fourth zone is used for returning the drums. The entire control system was designed by REUKO Klimaservice GmbH, which, together with DENIOS, has already gained considerable experience with ventilation systems in the pharmaceutical sector. The chamber separates the storage area directly from the high-purity production area. The issue of differing cleanroom classifications was resolved by means of tightly sealing doors that are interlocked. Drum transport presented a particular challenge. The drums are moved on pallets using a pallet truck from the storage side to the chamber and then picked up by a gripping device. For this purpose, a gripping system from DENIOS’s standard range was tested at the customer’s site and subsequently optimised for the GMP area. On the production side, the drums are then removed using a pallet truck suitable for cleanrooms. This prevents any contamination from being carried over via the pallets.
Results and customer benefits
To ensure a perfect fit, the entire system was designed using 3D modelling in Germany (Bad Oeynhausen). This design took into account not only the installation via a small hatch in the 22-metre-high roof, but also the manoeuvring and positioning of the chamber. The chamber fits seamlessly into the existing space and has been fitted to the room all round. Above the chamber, on the storage side, there is an access point for maintenance of the fan and heating coil. The control systems and steam regulation for the heating are housed in the directly adjacent control room. The precise execution of the work and the chamber’s innovative operability are the hallmarks of this project. With this new production facility, the Grenzach site has established a very solid foundation for the future. The work processes have been optimised to an exceptional standard, not least thanks to the DENIOS heating chamber.
