The JEL Konti II in pharmaceutical design
Screening of pellets – continuously and hygienically
Pharmaceutical pellets usually consist of active ingredients, excipients and additives that are put together according to a specific recipe. For this purpose, they must be available in precisely defined quality, i.e. in the appropriate particle size spectrum and without agglomerations. Only then the formulations can be precisely dosed and subsequently processed into precisely filled capsules or break-resistant tablets.
Screening machines therefore play a special role in quality assurance. On the one hand, they ensure that no foreign bodies get into the product. On the other hand, they guarantee that the materials are available in the optimal particle size for further processing. However, even dry, free-flowing pellets like the one in this project example have their pitfalls. Unwanted agglomerates, adhering dust particles and grain sizes that lie outside the optimal grain spectrum reduce the quality and have to be separated.
For this application, we have implemented a mobile, compact and at the same time economical solution for coarse and fine separation. Mandatory for use in the pharmaceutical sector: conformity with relevant directives.
The JEL Konti II vibration screening machine seen from above – adapted to the customer’s individual requirements: A mobile and pharmaceutical solution in hygienic design.
Frame and chassis are made of stainless steel (1.4401), as is the vibration screening machine itself. The frame is equipped with two additional round tubes with which the JEL Konti II can be pushed onto a lifting column provided by the customer. Two collection bins for separated oversize and undersize particles are integrated directly into the frame below the screening machine.
JEL Konti II in a Hygienic Design version
The housing of the screening machine is mounted in an oscillating manner by spring connections so that the transmission of vibrations from the screening machine to the frame is reduced to a minimum. In this case, spiral springs are used for better cleanability. To reduce the surfaces for deposits, round instead of square profiles are installed, with a roughness depth of Ra of </= 1.6 µm. Surfaces that get in contact with the product inside the screening machine are e-polished and have a roughness of Ra </= 0.8 µm.
The vibration screening machine is configured as a double-decker with two screen decks. The sieve housing is completely closed. The cover of the housing is reinforced and divided into two parts. This makes handling easier. The individual cover segments are fitted with quick-release clamps and are easy to open. A distribution plate is installed directly under the inlet spout to ensure that the material to be screened is distributed evenly over the upper screening deck.
Each of the two sieve decks covers an surface of 0.45 m². To change the sieve inserts, they can be pulled out easily from the front of the sieve housing like a drawer. Clamping bars inside the machine, which are handled from the outside with star grips, hold the sieve inserts in place during the sieving process. The JEL Konti II can thus be operated completely without tools.
When the sieve insert is pushed in and secured, the screening machine is closed dust-tight thanks to silicone clamping profiles. The mesh of the sieve inserts is hygiene-compliant according to DIN ISO 9044 and also made of stainless steel (1.4401).
Screening pellets made easy
Continuous feeding, dust-tight operation, sharp results
The JEL Konti II is fed continuously with product. Tri-clamp connection and rubber seal at the inlet spout ensure dust-tightness during product feed. The outlet spouts for undersize, oversize and suitable particles are fitted with BMF fittings.
To adapt to different product characteristics, the sieve inclination, the setting angle of the two vibration motors and the vibration amplitude of the sieve machine can be adjusted. Since the product flows well but tends to stick, an additional ultrasonic cleaning system has been integrated. It is automatically switched on at defined intervals, ensuring the permeability of the sieve inserts on a permanent basis.
Adjustable vibration motors
Screen decks with ultrasonic cleaning
Easy change of the sieve inserts
When the screening machine is fed, the product falls from above through a feed hopper and is distributed evenly on the screen feeder below the inlet by a distribution plate. Once the product has passed the upper deck, only the coarse grain remains on it. It is removed from the coarse material outlet and collected in a collection container. After passing the second screen deck, fine and good grain are also separated. The fines are ejected into the second collection bin. The good material in the right size fraction is transferred to a large container for further processing.
Components that are too coarse reduce the quality and are separated out.
Too fine parts also interfere. They are also ejected.
Level detectors send an alarm when the full containers need to be replaced.
The two stainless steel bins for the collection of coarse and fine grains each hold 30l and are placed directly below the respective outlet. Matching adapter covers with beading for dust-tight docking and undocking of the containers complete the bin holder.
And of course, suitable safety mechanisms have also been thought of: on the one hand, the solution is equipped with a drum centring device that prevents the bins from slipping during operation. On the other hand, it is equipped with fill level sensors in a clampable design. The sensors are inserted into the barrels via a plug-in connection on the lid.
If the collection bins are full, an acoustic alarm is given. A visual alarm is also integrated. The operator then stops the system, the sensors are pulled out, the bins are unlocked and emptied. Then production can continue.