How To Choose A Suitable WIP Or CIP Sieve Machine? - Senieer

Leakage of highly active drugs will seriously endanger the safety of operators – therefore, as more and more highly active compounds are approved as new drugs, pharmaceutical companies have more and more requirements for the closed production of tablet drugs . Drugs of OEB 3 level (OEL<100 µg/m3) need to be evaluated during the production process whether high-containment production is required, while drugs of OEB 4 (OEL<10 µg/m3) and OEB 5 (OEL<1 µg/m3) In the production process, highly airtight production equipment and technology must be applied. In this regard, this paper introduces the types of tablet sieves, analyzes the problems that should be considered when selecting the type of tablet sieves in the closed tablet pressing process, and compares the respective advantages of WIP sieves and CIP sieves.

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Sieve machines can be divided into non-dust-tight type, dust-tight type, WIP type and CIP type, etc. Of these, non-dust-proof dust collectors are the most common type, but these sifters are not suitable for toxic or highly reactive formulations as they allow dust to escape during operation, especially if there is not enough air for dust collection in the case of. In addition, non-dust-tight machines also need to be disassembled and cleaned, which will expose operators or cleaning personnel to dust in the air.

Dust-proof sieves have positive connections to both upstream and downstream equipment and are fitted with gaskets and seals to prevent dust migration during operation. But like non-dust-tight sieves, they also need to be disassembled for cleaning and are not suitable for hazardous or highly reactive formulations. Therefore, to protect operators and cleaning personnel in hazardous applications, a wash-in-place (WIP) or clean-in-place (CIP) sieve machine must be used.

WIP sieves are dust and water resistant, providing an effective level of containment during operation. WIP machines allow water or water and detergent to be introduced into the machine and all areas within the machine will be fully wetted so no disassembly is required; the water will flush the entire interior of the machine, preventing dry powder exposure and removing most powder from the machine. This allows the operator or cleaning crew to safely disassemble the machine for final manual cleaning and drying without the risk of dust.

Like WIP sieves, CIP machines are dust and watertight and provide an effective level of containment during operation, but they require the use of effective cleaning procedures to verify that no material remains in the machine after cleaning. CIP machines can be completely cleaned and dried without disassembly. They require no human intervention, allowing the line to run on another product or batch as soon as the CIP machine has finished cleaning and drying.

Part 1 Factors To Consider When Choosing A WIP Or CIP Sieve

While WIP and CIP sieves cost more than dust-tight and non-dust-tight sieves, the additional cost of these two types of machines is usually a fraction of the cost of hermetic tablet presses and peripheral equipment. Since dust collectors can remove harmful dust from tablets, it is important to choose a suitable tablet sieving machine. The tablet sieve is also part of the closed system, and the tablet press, sieve and closed tank must work together seamlessly.

In order to adapt the sieve machine to actual production and needs, users need to customize its functions and operations. To do this, a User Requirements Specification (URS) should be developed to document all system expectations and approved by all user groups. Before purchasing a WIP or CIP sieve machine, users should consider the following questions:

What Is Our Normal Production Requirement?

How dangerous are our products? What is the Occupational Exposure Limit (OEL) range? What is the time-weighted average tolerable concentration for occupational exposure limits? Does the material require manual handling?

• Is the special sieve machine easy to assemble and disassemble?

• What layout do we need to handle upstream and downstream processes?

• How will we control the flow of water? Are there restrictions on water use?

• How will we manage the make-up air for dust collection?

• How will we handle equipment failure?

• Whether metal detection is required in the production process?

• Do we need a diverter for multiple tanks?

Normal Production Requirements

Determine the demand for capacity and dust removal efficiency, as well as the requirements for the relevant physical parameters of conventional sieving machines. This includes tablet size and shape, press production speed, press exit height, and barrel height.

Dangerous Product

Occupational exposure hazards for products and powders are classified into 5 levels, OEB 1 to 5, where 1 is the highest level for which exposure is permitted and 5 is the lowest level. The measurement unit of OEL level is μg/m3, ～ μg/m3 is OEB 1, and OEL<1 μg/m3 is OEB 5.

At this point, the WIP or CIP machine leak-tightness should be verified using the Standardized Measurement of Particle Concentration in Equipment (SMEPAC) guidelines. SMEPAC is a guideline sponsored by the International Society for Pharmaceutical Engineering (ISPE), which gives performance testing standards that allow pharmaceutical companies to accurately compare machines.

Assembly And Disassembly

Evaluate the ease of assembly and disassembly of the desired sieve. For example, are special tools and procedures required for disassembly and reassembly?

Layout

Consider the desired layout and determine how the machine will interface with upstream and downstream equipment, and how connections will be made and broken when the machine is dismantled and cleaned. These connections may be split butterfly valves, other closed valves, or continuous liner systems, each of which requires vertical space that must be accounted for in the layout. The tablet press connection, the discharge chute from the tablet press to the tablet sieve, the connection to the tablet sieve, metal detectors and tanks must all be WIP or CIP capable to ensure no dust escapes from the system.

Water Control And Use

Determine the discharge of water during a WIP or CIP process. Water usage is also a consideration, as pharmaceutical companies must collect some hazardous materials and dispose of them in hazardous waste collection facilities. By minimizing water usage, disposal costs can be kept low over the life of the machine. If off-line cleaning is to be performed, it must be determined how to disconnect the sieving machine from upstream and downstream equipment in a closed manner.

Dust Collection

Ensuring continuous dedusting in the sieve, with no fluctuations in flow and vacuum pressure throughout the batch, is necessary to maintain proper system performance. It should be determined in advance how the make-up air for dust collection will enter the sifter and what will happen if it fails. For example, if the sieve machine is positive pressure, will the positive pressure cause dust to be blown into the clean room?

Since the tablet press, sieve and hopper are all connected in series, there may be a separate dust collection system for the tablet press and sieve. Faced with this situation, the dust collection system must be properly balanced. If they are not balanced, the dust collection airflow of the tablet press is stronger than the dust collection airflow of the sieve machine, then the tablets may be pulled back into the tablet press. In addition, the dust airflow can cause problems for the tablets to flow out of the sieve machine and into the bin.

Equipment Failure

Determine how to handle all possible equipment failures. What is the company’s contingency plan in the event of a breakdown? What if the machine has to be opened during production? Does the company have a plan to safely open the machinery in an emergency using personal protective equipment?

Metal Detection

Determine the need for metal detection. Determine how to introduce the test piece of the metal detector in a closed manner. How to remove the test piece in a closed manner after it has passed through the metal detector? How to remove rejected pills from a metal detector in a closed fashion?

Shunt

Determine if a diverter is required at the discharge of the sieve machine. The splitter allows the use of multiple tanks to avoid shutting down the tablet press and screener when changing tanks.

Part 2 Comparison Between WIP Sieve And CIP Sieve

The main problem hindering automatic cleaning of sieve machines is that sieve machines have many nooks and crannies, and it is difficult for an automated system to clean them in a reviewable and fully verifiable manner. Therefore, WIP sieves are more common than CIP sieves.

In theory, CIP sieves appear to save cleaning time, but in reality, verifying the consistency of cleaning for each product is time-consuming, requiring electronic storage of the CIP recipe in the machine’s control system. Also, in addition to the cleaning process, the drying process needs to be validated to ensure that the sieve machine is completely dry before production starts again.

Part 3 Summary

The pharmaceutical industry is a highly regulated industry. When a pharmaceutical company produces or changes any product, it must report its production process to the State Drug Administration. This is an extremely tedious and complicated process, which will not only affect production efficiency, but also increase unnecessary losses for the enterprise. Therefore, when pharmaceutical companies choose WIP and CIP sieve machines, they need to fully consider how to make upstream and downstream equipment better compatible with each other, and do a lot of thinking and coordination to ensure their effectiveness. An experienced supplier of WIP and CIP sieve machines can help customers deploy a robust system that provides a high level of effective, trouble-free containment protection for their specific application.

1.What is a Vibrating Sieve Machine?

Vibrating Sieving Machine

A vibrating sieve machine is a commonly used tool to eliminate oversized or unwanted particles from raw materials before making a product. This is also known as a sieving machine which is intended to simplify powders and make them uniform and even.

The machine is small and compact in structure but offers a wide range of applications in various industrial sectors as it helps in manufacturing the best quality product. The separation of particles is based on the mesh size of the machine which can be selected upon your requirements.

The reason for vibration or gyratory motion is to move particles and separate them more efficiently. Due to its high responsibilities hooked with the lowest ratio of dust formation, this is high in demand globally.

2.How Does a Vibrating Sieve Machine Benefit You?

Nevertheless, a vibrating sieve machine is an essential tool used in almost every manufacturing industry. There are several benefits behind this machine, some of which are discussed below:

Innovative Design

Maximum and uniform separation of Particle- Picture Courtesy: Russel

The vibrating sieve machine ensures an efficient movement of sieving particles across the screening plate that helps in the separation of materials effectively with enhanced performance.

Modulated Vibrating Speed

Controllable sieving speed- Picture Courtesy: Dotomox

The machine has the ability to adjust fine tuning that depends from process to process and based on the characteristic of particles requires a specific speed.

Particle sizing of dry or wet products

Nature of particles- Picture Courtesy: Lawson

The vibrating sieve machine is a flexible option that is capable of running particles whether it is dry or wet. That’s why this is considered an ideal machine for several industries.

Dust-proof Sieving

Dust- Proof Sieving- Picture Courtesy: ATA Scientist

This machine is highly productive and offers you safe sieving as the machine features a dustproof covering that enables user safety and meets high production requirements in a safe manner.

Fast & Easy to Clean

Flexible to Clean- Picture Courtesy: Particle Technology Lab

Due to its robust designs and stainless steel body structure, it is quick to clean; the sieve containers are flexible to remove and easy to mount and clamp using a ring.

3.What are the Industrial Applications of Vibrating Sieve Machine?

The vibrating sieve machine has multiple sieving and screening application used for various purposes in several industries. Here are some important industrial applications of vibrating sieve machines:

Food & Beverage Industry

Applications in food & Beverage

A vibrating sieve machine construction is made up food food-grade materials that efficiently separate impurities and offering same same-sized particles. In food and beverage industries, it is used to sieve salts, sugars, spices, various flavoring and seasoning powders such as coconut powder, cocoa powders, mustard powders, etc.,

Chemical Industry

Vibrating sieve chemical

The vibrating sieve machine is broadly used in the chemical industry as it is safe to use and achieve the optimum range of chemical powders by using gyratory motion which is used to eliminate the wrong size range of particles that are not intended for particular application. For example, bleach powder, acidic powders like citric acid, boric acid etc, basic powders, and others.

Ceramics Industry

Ceramic powders vibrating sieve machine

In the ceramic industry, the sieving action is required to attain particle grading and separation. Thus, screening is significant in the processes of the ceramic industry. The material sieving includes clay, talc, and sand, which must be sieved before final processing.

Pharmaceutical Industry

Vibrating sieve machine for particles of Pharma

A vibrating sieve machine plays a vital role in the manufacturing of pharmaceuticals ensuring persistent quality and safety. In the preparation of medicines, accurate grading and uniform-size particles are paramount which is achieved by the application of a vibrating sieve machine. The preparation of tablets, powders, ointments, lotions, capsules, pills, granules, syrups, antibiotics, painkiller solutions, and other products needs proper sieving prior to manufacturing.

Minerals Industry

Limestone powder from vibrating sieving machine

This machine is broadly applied in the mineral industry and is specifically designed to deal with minerals of different sizes. the machine is capable of running large production batches with high efficiency. The primary mineral sieving involved are sulfur, salts, coals, graphite, limestone, and others.

4.What are the parts of the Vibrating Sieving machine?

Allpack Vibrating Sieve Machine

Feed Inlet

The materials to be sieved are introduced into a vibrating sieve machine via feed inlet which is also known as an entry junction.

The feed inlet is responsible for ensuring the proper entrance of material for sieving.

Dust Cover

As it names show, this part of the machine is responsible for subsiding dust formation which is generated during the sieving process. It helps in keeping the production facility clean and safe against respiratory problems.

Beam Loop

During the sieving process, the machine becomes stable and supported by a beam loop as it integrates parts of the machine connected and makes them unite to avoid dissembling.

Discharge Outlet

This is an existing junction where sieved particles are discharged out of the machine.

Machine's Base

The machine of vibrating sieve machine is made up of stainless steel and firm casting which offers maximum and great support.

Sieve Screen

This is the main unit or component of the machine which is responsible for filtering particles from the screen of the respective mesh size. The smaller particles pass through the perforated screen via vibrating force and larger ones remain left on the surface.

5.What Is the Working Principle Of a Vibrating Sieve Machine?

The working principle of vibrating sieve machine

Level 1- Punching Materials The working of the vibrating sieve machine. begins when you feed raw material into the unit using the inlet portion.

When you see the diagram, punch material screens first and leave the unit from the exit. The punching material is mainly known as large size particles that are mostly presented in irregular shapes.

Therefore, to prevent sieve clogging, large size particles filters first.

Level 2- Mesoporous Materials

Now , vibrating sieve machine. typically holds material with small to medium size particles which is comparatively more challenging to filter than large size particles. By helps of agitation, mesoporous material leaves the system.

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Level 3- Small Materials

The more finest and small size particles are sieves evenly from this level. In this level, you may receive powders that are suitable for pharmaceutical preparations, such as tablets, capsules, and other purposes.

6.What Is a Type Of Vibrating Sieve Machine?

There are different types of vibrating sieve machines, depending on the size, design, and operational principle of the vibrating sieve machine.

According to Size

Lab Vibrating Sieve Machine

Lab Vibrating Sieve Machine

It is also called a laboratory sieve shaker and is used in small industries and the research and development sector. It has a smaller footprint, typically mounted on a smaller frame. The lab vibrating sieve machine is accommodated on the benchtops and is a portable unit.

It usually processes and separates smaller test batches.

Industrial Vibrating Sieve Machine

Industrial vibrating sieve machine- picture courtesy: eur.vevor

It is a large industrial type of vibrating sieve machine, that processes larger batches of raw materials. It often contains multiple screens that aid in higher separation efficiency. It is employed in larger industrial settings as it is used in continuous separation.

The industrial vibrating sieve machine is larger so it needs more floor space.

According to Design

Circular Vibratory Sieve Machine

Allpack Circular Vibrating Sieve Machine

This machine has a typical design with a circular frame and circular mesh screen. The particles in this machine are sieved by the circular vibration. The materials move towards the centre of the circular mesh and then are separated. It has the simplest design of the vibrating sieve machine. Due to its circular shape, it has a lower footprint as compared to other types of vibratory sieve machines.

Rectangular Vibrating Sieve Machine

Allpack Rectangular Vibrating Sieve Machine

In contrast with the circular vibrating sieve machine, this machine consists of a rectangular-shaped structure with a rectangular screen. This rectangular-shaped design has the benefit of larger sieving areas over traditional circular vibrating sieve machines.

Linear Vibrating Sieve Machine

Linear Vibrating Sieve Machine- Picture Courtesy: Dingcoma Coporation

It has a straightforward linear type design in which linear vibrations of the machine sieve the substances. It uses forward and backward vibrational motion produced by the motors to move materials on the mesh screen, leading to their separation. Because of its simpler construction, it is easy to clean, maintain, and run this equipment.

Square Swing Vibrating Sieve Machine

Square Swing vibrating Sieve Machine

The mesh screen in this type of vibrating sieve machine is in square shape. This provides more sieving area as compared to a circular vibrating sieve machine. The sieving assembly moves forward and backward to filter the smaller particles from larger-sized particles.

Due to the larger separation area, it has more sieving capacity. It prevents clogging of the mesh screen by its swinging motion.

Direct Discharge Vibrating Sieve Machine

Direct Discharge Vibrating Sieve Machine

This type of vibrating sieve machine, as the name suggests, directly removes the undesired large particles from the bottom and increases the filtering efficiency. It behaves like a typical vibrating sieve with its vibrating motion. This motion directs the separation of smaller particles from the mesh screen while larger particles are removed from the discharge port located at the bottom.

According to the Mode of Operation

Ultrasonic Vibrating Sieve Machine

Ultrasonic Vibrating sieve Machine

It is also referred to as an ultrasonic sifter. In this machine, ultrasonic waves and vibrations are used to filter the materials. The weak bonding between particles is broken down by the ultrasonic waves and vibrations. It decreases the size of particles in turn increasing their separation efficiency.

It removes undesired particles that boost end-material quality.

Swing Vibrating Sieve Machine

Swing Vibrating Sieve Machine

This machine is also called a swing screen. As compared to a typical vibrating sieve machine that has vertical motion, the swing vibrating sieve machine moves in the horizontal direction back and forth to separate the particle materials. This counteraction motion boosts the sieving efficiency of the machine.

Centrifugal Vibrating Sieve Machine

Centrifugal Vibrating Sieve Machine

It is also called rotex sifter. The principle of centrifugal force and vibration are combined in this machine for the separation of the particles. A rotating paddle present in this machine generates the centrifugal force while the vibration is produced by the mesh screen. Both these forces increase the separation efficiency and decrease the chances of clogging.

It separates materials at a much faster rate than a simple vibrating sieve machine.

Gyratory Vibrating Sieve Machine

Gyratory Vibrating sieve machine

It consists of screen mesh which is placed at the frame of the machine. It uses gyratory motion to separate the particles.

This motion leads to the movement of particles along the walls of the gyratory vibrating sieve machine which in turn causes the passing of smaller materials from the mesh screen while larger particles remain at the mesh screen.

It can easily accommodate batches of higher volumes and has high production capacity.

7.What is the mesh size of the Vibrating Sieve Machine?

Application of Mesh Size in Vibrating Sieve Machine.

The mesh size of the vibrating sieve machine is the size of the screen mesh installed on the vibrating sieve machine. The mesh size of the mesh screen is the size of the aperture or holes present per inch or per centimetre of the mesh screen. These openings or holes are the main parts that are used for the sieving of materials.

Mesh size is an important parameter that plays a role in filtering different materials. The highest mesh size means the highest aperture size. It processes and separates particles with larger sizes. In contrast, a smaller mesh size means a smaller aperture size, mesh with smaller sizes filters fine and ultrafine particles.

Units of Mesh Size

Mesh size is measured in different units like a millimetre, micrometre, or mesh number per inch.

1 mm= µm

Here is a chart for your understanding.

Mesh Aperture (mm) Mesh Aperture (mm) Mesh Aperture (mm) 2 12.5 50 0. 300 0.050 4 6 60 0.28 400 0. 8 3 70 0.244 500 0. 12 1.6 80 0.18 600 0.026 16 1.25 90 0.16 800 0.022 20 0.9 100 0.15 0.015 30 0.6 150 0.1 0.008 40 0.45 200 0.074 0.003

It is observed from the above-mentioned chart that a smaller mesh count has a smaller number of openings or aperture per inch of the mesh screen but has a higher aperture or mesh size, therefore, the aperture diameter is higher. Conversely, the larger mesh count has a greater number of openings per inch, consequently, the diameter of the aperture or mesh size is less.

8.How Do You Determine the Size Of The Mesh In The Vibrating Sieve Machine?

Particle size of material- Picture Courtesy:Fp

The mesh size or count is usually determined by the size and characteristics of particles that need to be filtered. The calculation of mesh size is also dependent upon the size of the batch.

Particle Size

Particle Size and Mesh Size

If your desired particle size is smaller, then go for the mesh size with the smaller mesh count. This mesh has a larger aperture diameter so it is easily used in coarse filtration.

For example, the mesh with a size of 4 mm or above is used for sieving the stones and other larger impurities.

On the other hand, select a smaller mesh size if the target particle size is smaller. The sandy materials are sieved with a mesh size of 1mm to 400 µm. These mesh sizes are used for medium to fine particle separation.

For fine or ultrafine separation of particles, the smallest mesh sizes are used having sizes of 10 µm or below.

Shape of Particles

Shapes of Particles and Mesh Size

Shapes of particles also determine the mesh size of the vibrating sieve machine. If particles have irregular shapes, then a larger-sized mesh is needed for processing such shaped particles This mesh size has a larger-sized opening, so particles are easily passed without clogging the mesh screen.

For round-shaped particles or consistent shape particle size, a mesh screen with a smaller aperture size is used. This mesh size is used for their superior sieving.

9.What Is the Difference Between A Sifter And A Vibrating Sieve Machine?

Allpack Vibrating Sieve Machine

Sifter and vibrating sieve machines, both are used for filtration and separation of the materials. There are some notable differences between these two machines. Some differences are listed for your information.

Feature Sifter Vibrating Sieve Machine Operation This machine uses manual agitation for sieving the materials. Manual agitation is achieved by hand cranking or motors. This machine with the help of vibratory motion separates the materials. Motors are used for powering the machine. Applications It is used in the small-scale industries like bakeries and food sectors. It is used for delicate filtration, in which particles may degrade upon vibration. It is used in large-scale industries because of its high throughput. A vibrating sieve machine is typically employed for vibration-resistant materials. Size It is typically smaller in size, so. it is convenient to move these sifters. Vibrating sieve machine has a higher footprint and are heavier in weight. Production Capacity It is used for smaller batches and light-duty applications. Sifter is utilized for batch processing. It is used for large batches and has larger efficiency and speed. This machine is more suited for continuous processing applications. Precision The sifter machine has low precision. The vibrating sieve machine has high precision. Cost Due to its simple construction, the sifter has a low initial investment. Since it is a complex configuration, so this machine costs more.

10.What Are the Major Problems And Solutions for Vibrating Sieve Machine?

As a vibrating sieve machine is the most common tool used for screening due to high efficiency and precision; it also confined to some unwanted problems also. How to deal with them? Our team has comprehensively described them below, have a look:

Machine Doesn’t Sieve Properly

A Vibrating Sieve Machine- Picture Courtesy: Voor 'T Labo

Due to high quantity of uneven raw materials, screen of the machine may be damaged, or excessive oil addition may lead to cause this problem.

This can be solved by installing the machine on firm and even place, check if electrical connections is smooth and uninterrupted. Replace the damaged sieve or screen and check if machine works satisfactorily.

Clogging and Binding of Particles

Anti binding balls used in vibrating sieve machine

This is common problem where machine sieves blogged due to binding of materials and affect overall process. To solve this problem, anti-static or anti-binding devices are introduced such as ultrasonic machines which prevent binding of particles.

Follow the regular cleaning, by these chances of clogging also minimizes.

Conclusion

Certainly, a vibrating sieve machine is ideal to screen and separate particles for mass production in various industries, it can be wet and dry particles of various sizes and shapes. The machine ensuring facilitation of high and even particles to make your product with high quality. If you’re looking for purchasing machine for production facility; then please contact Allpack Team to avail guidance and quotation.

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