24/04/2009New Telstar sterilization facility for BD in Mexico

Telstar Technologies has supplied and installed a complete sterilization facility for BD in Mexico.

The whole project included three 72 m³ ETO sterilization chambers   for processing of syringes in palletized cardboard boxes. In addition to zones for pre-conditioning and aeration, the installation also includes a completely automatic loading and unloading system. The scope of supply included: ancilliary equipment, such as ETO gas dispensing system, a clean steam generator, an integrated production parametrical release device and a series of ETO concentration sensors for detection of potential leaks in the working area. All these equipment elements are controlled by a centralized Supervision, Control And Data Acquisition system (SCADA). The entire project has been designed and developed using the latest technology and in accordance with the most up-to-date regulations such that the process strictly fulfills the ATEX regulation for working in explosive atmospheres, and the SIL 2 regulation for personnel protection. 

Telestar Technologies has been supplying ETO sterilizers to BD since 1992, at all times in keeping with worldwide safety regulations. As safety standards are raised worldwide, it was recognised that additional requirements for these units might be necessary. Former design and operation criteria were submitted to an exhaustive functional review in this project. Three different types of studies were carried out:  Hierarchy of Risks, Risks Analysis (HAZOP) and Failure Mode and Effect Analysis (FMEA). A safety PLC was integrated for orchestrating control of the entire installation in accordance to regulations required to comply with the SIL 2 classification.

Moreover, three important elements of the mechanical construction of the sterilizers were redesigned, namely: the air circulation fan; the jacket, and; the locking system for the doors.  Firstly, an external high volume centrifugal fan has been installed on top instead of several magnetically coupled fans. This fan takes the air from the lower portion of one end of the chamber, and transfers it to the upper portion at the other end, via large diameter tubes. As a result, functional efficiency has been improved and the use of magnetic joint connections (which are very complex and expensive) has been avoided, leading also to a reduction of costs associated with maintenance. Tests carried out at factory demonstrated a maximum temperature difference of 0.4ºC across the 60 probes installed in the 72m³ chamber, during thermal mapping. Moreover due to the saving of the useful space, the chamber dimensions are smaller for the same loading capacity.

Secondly, the new design with discontinuous jacket, made of carbon steel, is preferable from the point of view of economics and due to the air recirculation system; the efficiency of the heating system was also improved.

Finally, the automatic locking system for the doors was based on a mechanism of rotary eccentric cams driven by electric motors. This new design improves the efficiency and the safety while at the same time reducing costs.

Thanks to this new sterilization facility, BD will improve the efficiency of its cycles, achieve compliance with current emission regulations and enjoy reduced costs, while at the same time ensuring the safety of its workforce.