DryCon®: Customer-Oriented Containment for Tablets
Safe and economical solution from KORSCH with innovative misting technology
With the DryCon® system, KORSCH offers an economical and safe containment solution for tablet production up to OEB level 4. The innovative misting technology binds dust particles by means of ultra-fine misting, increases operator protection, and reduces cleaning effort – for maximum safety, efficiency, and flexibility in the processing of highly potent active ingredients.
The optimal dimensioning of containment systems is crucial for striking a balance between safety, efficiency, and cost-effectiveness. If containment solutions are oversized, users incur unnecessarily high costs. The DryCon® kit from KORSCH offers a well-thought-out concept: It is a flexible and economical solution for the safe processing of powders in tablet production, and has been proven to meet the requirements of containment level OEB 4. The innovative misting technology developed by KORSCH also reduces dust exposure in the compression zone by binding dust, effectively increasing operator protection after production and when opening and cleaning the tablet presses.
DryCon®: Save costs with maximum safety
At the heart of the system is the Restricted Access Barrier System (RABS), which uses negative pressure control in the compression zone, window locks, and reinforced dust-proofing on the make/ break connections, creating a controlled working environment. It ensures that no powder particles are released in an uncontrolled manner during production. The system is equipped with glove ports, a Rapid Transfer Port (RTP) for charging and discharging, dust extraction, and quick-action stop valves, and can be equipped with continuous liners. Peripheral devices that meet the respective system’s OEB requirements can also be connected. For final cleaning, operators must wear personal protective equipment (PPE).
While Wash-in-Place (WIP) systems offer an even higher level of security, they are often not as cost-effective and less flexible in handling. In many applications, a DryCon® kit is sufficient to ensure adequate operator safety while also making the start of production faster and more economical. This depends on the safety classification of the active pharmaceutical ingredient (API) by the customer as well as the API’s final concentration in the pressing mass.
Additional security mechanisms for OEB 4 requirements
As long as the negative pressure control and dust extraction systems are working reliably, there is no risk even when processing highly active ingredients. However, in the event of a system failure – due to an interrupted power supply, for example – there may be acute danger to the operators. To prevent this risk, DryCon® technology for OEB level 4 offers additional safety mechanisms: In addition to the alarm triggered by pressure loss, quick-closing valves and a supply air filter give operators valuable time to leave the room safely. “We analyze each application individually and advise our customers specifically on the optimally dimensioned equipment. This allows us to deliver highly specialized, fully integrated solutions for safe and efficient operation,“ says Jochen Sommer, Global Sales Director of KORSCH AG, describing KORSCH’s approach.
Tablet press and peripherals factored in
The containment concept goes beyond the tablet press to consider the entire periphery, including dedusters, metal detectors, tablet testers, filters, and other connected devices. KORSCH thus offers its customers a complete solution for the tableting process, tailored to the requirements and conditions of the customer’s production. This ensures a continuous process chain with maximum safety. Jochen Sommer explains: “A KORSCH DryCon® tablet press as such is OEB-4-capable. However, the peripheral equipment must also be certified for OEB 4. Here, an accurate needs analysis saves considerable costs for the user. Our experts are very familiar with the guidelines and design criteria for OEB systems and advise our customers on the best options for integrating peripheral devices.”
Operator protection is a key focus when processing solid dosage forms. Closed containment solutions that allow safe operation without PPE are growing increasingly popular. This is also reflected in the demand. “We are seeing a high demand for DryCon® solutions – particularly if the application can reach OEB level 4 with them,” Jochen Sommer reports. The environmental aspect is also gaining importance. The safe handling of active ingredients helps to minimize their release into the environment. KORSCH offers an innovative solution with a new misting technology that significantly reduces dust formation in the compression zone by means of spray misting.
DryCon® plus misting: Additional protection through ultra-fine misting
The company developed the misting technology in close cooperation with a customer: specialized high-pressure nozzles produce a fine spray mist that binds even the smallest powder particles, thus minimizing the risk of exposure before the machine’s final cleaning. “Depending on the compression zone’s size, we install one or two nozzle units with four to nine nozzles each.
These are aligned in a way that ensures all of the machine’s surfaces are optimally wetted, effectively binding the dust in the compression zone. A handheld spray gun is provided for areas that are covered by machine parts; it can be operated comfortably via the glove ports,” explains Tobias Richter, Head of Mechanical Design for R&D at KORSCH AG.
Misting as an advantage in operator safety
Although misting does not replace complete cleaning, it supports companies in cleaning and preventing cross-contaminations in their tableting processes. It reduces the risk of active ingredient particles being released when the machine is opened, and confines contamination to a defined area. Jochen Sommer explains: “The system offers great added value, as it facilitates implementing the entire process in accordance with standard operating procedures (SOPs). Misting binds dust particles inside the machine, which allows machine parts to be transported safely and efficiently, for example from production room to washing machine – without the need for complex multiple packaging to prevent cross-contamination.”
Flexible containment solution with high added value
KORSCH’s DryCon® solutions offer an efficient and economical alternative to more expensive and not always necessary Wash-in-Place (WIP) solutions. A sophisticated combination of stable negative pressure control, dust-proof interfaces and optional misting technology achieves a high level of safety that meets the requirements of both OEB 3 and OEB 4.
Thanks to modular customization options and comprehensive advice from KORSCH, containment systems can be tailored exactly to the needs of the respective company – for safe, flexible, and cost-efficient tablet production. MEDELPHARM also plans to equip the STYL’ONE Evo Compaction Simulator with misting technology to offer additional optimization options for research applications.
