SYSTEM AND METHOD FOR CONTINUOUS PROCESSING OF POWDER PRODUCTS

Abstract

A system for continuous processing of powder products includes a first inlet configured to input a first dry powder product, a second inlet configured to input a second dry powder product, and a dry powder mixing device that mixes the first dry powder product together with the second dry powder product to form a product mixture. An outlet dispenses the product mixture from the dry powder mixing device. A production machine is included and has a powder feed frame comprising a feed frame inlet connected to the outlet of the dry powder mixing device. The outlet of the dry powder mixing device is positioned at a lower level than the feed frame inlet. A product conveying device is connected between the outlet of the dry powder mixing device and the feed frame inlet to continuously convey the product mixture from the dry powder mixing device to the feed frame inlet.

Claims

1-31. (canceled)

32. A system for continuous processing of powder products, the system comprising: a first inlet configured to input a first dry powder product; a second inlet configured to input a second dry powder product; a dry powder mixing device comprising, an inlet configured to connect to the first inlet to accept the first dry powder product and further configured to connect to the second inlet to accept the second dry powder product, wherein the dry powder mixing device is configured to mix the first dry powder product together with the second dry powder product to form a product mixture, and an outlet configured to dispense the product mixture from the dry powder mixing device; a production machine comprising a powder feed frame comprising, a feed frame inlet connected to the outlet of the dry powder mixing device, wherein the outlet of the dry powder mixing device is positioned at a lower level than the feed frame inlet of the production machine, and a feed frame outlet; and a product conveying device connected between the outlet of the dry powder mixing device and the feed frame inlet of the production machine, wherein the product conveying device is configured to continuously convey the product mixture from the outlet of the dry powder mixing device to the feed frame inlet of the production machine.

33. The system according to claim 32, wherein the continuous processing of powder products comprises a continuous production of solid dosage forms in direct processing, wherein the production machine is configured to continuously produce solid dosage forms from the product mixture, and wherein the production machine further comprises an outlet for discharging the solid dosage forms.

34. The system according to claim 33, wherein the production machine is one of: (1) a tablet press; (2) a capsule filling machine; (3) and a granulation device.

35. The system according to claim 32, wherein the first inlet for the first dry powder product and the second inlet for the second dry powder product are arranged at a height level that is at least one of: (1) a same height level; and (2) a lower height level than one of: (a) the production machine; and (b) the product conveying device.

36. The system according to claim 32, wherein a height difference between the outlet of the dry powder mixing device and the feed frame inlet of the production machine is more than 1.50 m, and wherein an overall height of the system is less than 2.50 m.

37. The system according to claim 32, wherein the product conveying device is a pneumatic vacuum dense phase product conveying device, wherein a conveying line pressure drop of the pneumatic vacuum dense phase product conveying device is more than 0.5 bar, and wherein a cycle mass of the pneumatic vacuum dense phase product conveying device is no more than 2 kg in weight.

38. The system according to claim 32, wherein the product conveying device comprises a product conveying hose configured to convey the product mixture.

39. The system according to claim 37, wherein a solids loading ratio of the pneumatic vacuum dense phase product conveying device is more than 15.

40. The system according to claim 32, further comprising, an inlet hopper positioned at the inlet of the product conveying device, and a conical diameter reduction configured to reduce a diameter from the inlet hopper to the conveying line of the product conveying device.

41. The system according to claim 32, further comprising at least one of: (1) an inlet hopper positioned at the inlet of the product conveying device; and (2) an outlet hopper positioned at the outlet of the product conveying device, wherein a volume of either the inlet or the outlet hopper is no more than 0.5 liters in volume.

42. The system according to claim 32, further comprising an outlet hopper positioned at the outlet of the product conveying device, wherein a ratio of a height of the outlet hopper to a diameter of the outlet hopper is at least 2.

43. The system according to claim 42, wherein a positive pressure is applied in the outlet hopper.

44. The system according to claim 32, wherein the feed frame inlet comprises a vent opening.

45. The system according to claim 32, further comprising an inlet hopper of the product conveying device, wherein the inlet hopper comprises a vent opening.

46. The system according to claim 45, wherein the vent opening comprises a venting tube.

47. The system according to claim 32, further comprising a plurality of feeding and dosing devices, wherein each of the first inlet, the second inlet, and the inlet of the dry powder mixing device is connected to one of the plurality of feeding and dosing devices.

48. The system according to claim 47, wherein the plurality of feeding and dosing devices, and the dry powder mixing device comprise a feeding, dosing and mixing module, wherein the feeding, dosing and mixing module is arranged in a module housing.

49. A method for continuous processing of powder products, the method comprising: continuously providing a first dry powder product and a second dry powder product to a dry powder mixing device; continuously mixing the first dry powder product with the second dry powder product in the powder mixing device to form a product mixture; continuously providing the product mixture to an outlet of the powder mixing device; conveying the product mixture from the outlet of the powder mixing device to a feed frame inlet of a production machine using a conveying device, wherein the outlet of the powder mixing device is positioned at a height below that of the feed frame inlet; continuously processing the product mixture with the production machine; and discharging processed product from the production machine.

50. The method of claim 49, wherein the conveying device is arranged in a connection between the outlet of the dry powder mixing device and the feed frame inlet of the production machine.

51. The method according to claim 49, wherein the discharging of the processed product comprises discharging solid dosage forms of the product mixture from the production machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Embodiments of the invention are explained in more detail below with reference to drawings. The drawings schematically show:

[0052] FIG. 1 illustrates a perspective view of an embodiment of a system for continuous processing of powdered products;

[0053] FIG. 2 illustrates another perspective view of the embodiment of FIG. 1;

[0054] FIG. 3 1 illustrates a perspective view of another embodiment of a system for continuous processing of powdered products;

[0055] FIG. 4 illustrates an enlarged view of Detail A of FIG. 3;

[0056] FIG. 5 illustrates an enlarged view of Detail B of FIG. 3; and

[0057] FIG. 6 illustrates a perspective view of another embodiment of a system for continuous processing of powdered products.

[0058] In the drawings the same reference numerals shall denote the same parts.

DETAILED DESCRIPTION OF THE INVENTION

[0059] FIGS. 1 and 2 show an inventive system for continuous production of solid dosage forms in direct processing according to a first embodiment. The system comprises a production machine 10, in the shown example a rotary tablet press 10. The tablet press 10 is arranged in a production machine housing 12, in the shown example a tablet press housing 12. The tablet press housing 12 is integrated with a module housing 14 which contains a feeding, dosing and mixing module explained in more detail in the following. The tablet press housing 12 forms a system housing 16 together with the module housing 14. The system housing 16 comprises a plurality of windows 18 which may be opened in order to access components of the system. While in FIG. 1, the windows 18 are shown in their closed position, in FIG. 2 the windows 18 are shown in their open position for better explanation of the system components. A lower part of the module housing 14 is further cut away in FIG. 2 for a better understanding of the system design. As can be seen for example in FIG. 1, the tablet press housing 12 and the module housing 14 have essentially the same height. At the top of the system housing 16 the outlet 20 of a product conveying device 22 of the system can be seen. The inlet of the product conveying device 22 can be seen in FIG. 2 at reference numeral 24.

[0060] In FIG. 2, a first inlet 26 for a first powder product, such as an API, and a second inlet 28 for a second powder product, such as an excipient, can be seen. Furthermore, a third inlet 30 for a third powder product and a fourth inlet 32 for a fourth powder product can be seen in FIG. 2. The third powder product may for example be a further API or a further excipient. The fourth powder product may for example be an excipient, such as a lubricant. Each of the inlets 26, 28, 30, 32 is connected with a subsequent feeding and dosing device 34, 36, 38, 40 through a refill system 42, 44, 46, 48. Each of the feeding and dosing devices 34, 36, 38, 40 may be a loss-in-weight feeder. As can be seen in FIG. 2 the feeding and dosing devices 34, 36, 38, 40 are arranged in a row, in particular along a horizontal axis.

[0061] The feeding and dosing devices 34, 36, 38 and 40 are on the other hand connected with a mixing device 50. The mixing device 50 may generally be any type of dry powder mixer or blender. Mixing device 50 has a first inlet 52 which is connected with the feeding and dosing devices 34, 36, 38. A second inlet 54 of the mixing device 50 is connected with the feeding and dosing device 40. The mixing device 50 further has an outlet 56 which is connected with the inlet 24 of the product conveying device 22. The outlet 20 of the product conveying device 22 is connected with a feed frame inlet 58 of a feed frame 60 of the tablet press 10. The outlet 20 of the product conveying device 22 and the feed frame inlet 58 of the feed frame 60 of the tablet press 10 are connected through a vertical tube 62. The tablet press 10 further has an outlet 64 for discharging produced tablets.

[0062] In the following the inventive method carried out with the inventive system will be explained. During production the first, second and third powder product, provided at the first, second and third inlet 26, 28 and 30 are continuously provided to the first inlet 52 of the mixing device 50 through the feeding and dosing devices 34, 36 and 38. The fourth powder product provided at the fourth inlet 32 is continuously provided to the second inlet 54 of the mixing device 50 through the feeding and dosing device 40. The mixing device 50 continuously produces and provides at its outlet 56 a powder product mixture of the four powder products. The product mixture is continuously fed to the inlet 24 of the product conveying device 22. As can be seen for example in FIG. 2 the inlet 24 of the product conveying device 22 is positioned below the outlet 56 of the mixing device 50 such that the product mixture can flow from the outlet 56 to the inlet 24 via gravity. As can further be seen in FIG. 2 the outlet 56 of the mixing device 50, and thus of course also the inlet 24 of the product conveying device 22, are arranged at a lower height than the feed frame inlet 58 of the tablet press 10, and also than the outlet 20 of the product conveying device 22, said outlet 20 being positioned above the feed frame inlet 58 of the tablet press 10. The product conveying device 22 continuously conveys the product mixture fed to its inlet 24 to its outlet 20, and thus vertically lifts the product mixture to a greater height. From the outlet 20 the lifted product mixture is fed continuously to the feed frame inlet 58 of the tablet press 10 via gravity, said tablet press 10 continuously producing tablets from the fed product mixture and discharging the produced tablets at its outlet 64.

[0063] According to the above explained system configuration, it is possible to restrict the overall height of the system to less than 3.50 m, preferably less than 3 m, more preferably less than 2.50 m. To this end the product mixture may be vertically lifted by the product conveying device 22 over a height of more than 1.50 m, for example roughly 2 m. It can be seen in FIGS. 1 and 2 that the system inlets 26, 28, 30 and 32, and thus also the feeding and dosing devices 34, 36, 38 and 40, are arranged such that they do not extend above the height of the product conveying device 22 with its outlet 20. The above explained system and method configuration allows for a particularly compact construction with simple installation and improved accessibility of the system components, as explained above.

[0064] In FIGS. 3 to 5, a second embodiment of an inventive system is shown which is widely similar to the system shown in FIGS. 1 and 2. It also comprises a feeding, dosing and mixing module arranged in a module housing 14 and a production machine 10 arranged in a production machine housing 12. The production machine 10 can for example also be a tablet press, such as a rotary tablet press. However, the production machine 10 could also be for example a capsule filling machine or another production machine.

[0065] In the embodiment shown in FIGS. 3 to 5 the module housing 14 comprises two doors 66 for access to the inside of the module housing 14, instead of windows 18 shown in FIGS. 1 and 2. In FIG. 3 the doors 66 are shown in the open position for better explanation of the system components. At the top of the production machine housing 12 the outlet 20 of a product conveying device 22 of the system can be seen. The inlet 24 of the product conveying device 22 can again be seen near the outlet 56 of the mixing device 50. At the inlet 24 of the product conveying device 22 an inlet hopper 68 of conical shape is arranged. Connected with the inlet hopper 68 of the product conveying device 22 is a flexible product conveying hose 70 for vacuum dense phase conveying of the product mixture exiting the mixing device 50. In the enlarged view of FIG. 5 a conical diameter reduction 72 of the inlet hopper 68 can be seen.

[0066] The vacuum dense phase product conveying device 22 shown in FIGS. 3 to 5 further comprises a flexible vacuum hose 74 and a vacuum generation device 76. The vacuum generation device 76 creates a vacuum at the outlet 20 of the product conveying hose 70 through vacuum hose 74 which leads to a conveying of product mixture through the product conveying hose 70 from the inlet 24 to the outlet 20 of the product conveying device 22. A discharge valve at the outlet 20 of the product conveying hose 70 is intermittently opened and closed to discharge the conveyed product mixture into the feed frame inlet 58 of the production machine 10. To this end an outlet hopper 69 is provided at the outlet 20 of the product conveying device 22.

[0067] This intermittent conveying process leads to an intermittent rising and lowering of powder level in the feed frame inlet 58 of the production machine 10, as explained above. In order to avoid an undesired underpressure in the feed frame inlet 58 a vertical venting tube 78 with a venting opening at its top, is provided at the feed frame inlet 58 of the production machine 10. At the top of the venting tube 78 a dust extraction shroud 80 and a dust extraction hose 82 is provided leading to a dust extraction system for extracting any powder dust potentially exiting the venting tube 78 through the venting opening.

[0068] Since a similar problem with regard to a rising and lowering pressure due to the intermittent conveying exists at the inlet hopper 68 of the product conveying device 22, a corresponding venting tube 78 with a venting opening at its top is arranged at the inlet hopper 68, as can be seen in FIG. 5.

[0069] For feeding dry powder product to the dry powder mixing device 50 the system shown in FIGS. 3 to 5 again comprises a first inlet 26 for a first powder product, such as an API, a second inlet 28 for a second powder product, such as in excipient, and a third inlet 30 for a third powder product. The third powder product may again for example be a further API or a further excipient. Each of the inlets 26, 28, 30 is again connected with a subsequent feeding and dosing device 34, 36, 38 through a refill system 42, 44, 46. Behind the feeding and dosing device 34, 36, 38 further technical components are arranged, such as drives, which are only partly shown in housings 84, 86, 88 in FIG. 3. The rear wall 90 of the module housing 14 can also be seen in FIG. 3.

[0070] The production process with the system shown in FIGS. 3 to 5 is essentially the same as explained above for FIGS. 1 and 2. Powder products are fed continuously through the inlets 26, 28, 30 via the refill systems 42, 44, 46 and the feeding and dosing devices 34, 36, 38 via a hopper 92 to the inlet 52 of the mixing device 50. The dry powder products fed to the mixing device 50 are continuously blended in the dry powder mixing device 50 and discharged through the outlet 56 of the mixing device 50 to the inlet 24 of the product conveying device 22, in particular the inlet hopper 68. The vacuum dense phase product conveying device 22 conveys the product mixture through the product conveying hose 70 to the feed frame inlet 58 of the production machine 10, as explained above. In the production machine 10 the product mixture is continuously processed to products, such as solid dosage forms, like tablets or capsules. The produced products are discharged from the production machine 10 through outlet 64.

[0071] A further embodiment of an inventive system is shown in FIG. 6. The system shown in FIG. 6 comprises two feeding, dosing and mixing modules arranged in two module housings 14. The feeding, dosing and mixing modules with their module housings 14 may be embodied as explained for the system shown in FIGS. 3 to 5. In FIG. 6 the doors 66 of the module housings 14 are closed. A further difference between the system shown in FIG. 6 and the system shown in FIGS. 3 to 5 is that the system according to FIG. 6 comprises two production machines 10, each arranged in a production machine housing 12. The production machine 10 shown on the left side in FIG. 6 could for example be a tablet press, such as a rotary tablet press, or a capsule filling machine. The production machine 10 as shown between the two feeding, dosing and mixing modules could for example be a granulating device, such as a roller compactor or similar. In the first feeding, dosing and mixing module, shown on the right hand in FIG. 6, different dry powder products are continuously blended in a dry powder mixing device 50, as explained with regard to the above embodiments. The powder mixture is then conveyed through a product conveying hose 70 of the product conveying device 22 of the first feeding, dosing and mixing module, which again is a vacuum dense phase product conveying device, to the feed frame inlet of the subsequent first production machine 10, for example the granulating device. In this granulating device the product mixture is granulated to produce granule products. The granule products are then conveyed through a conventional granule conveying device 94, which could be any suitable granule conveying device, to one of the inlets 26 of the subsequent second feeding, dosing and mixing module. Further products may be entered into this second feeding, dosing and mixing module via the further inlets 28 and/or 30. The provided powder products, including the granule products, are then again continuously blended in the dry powder mixing device 50 of the second feeding, dosing and mixing module and subsequently conveyed through powder conveying hose 70 of the product conveying device 22 of the second feeding, dosing and mixing module, which again is a vacuum dense phase product conveying device, to the feed frame inlet of the second production machine 10, for example a tablet press or a capsule filling machine. In the second production machine 10 products are produced from the provided powder mixture, for example tablets or capsules, which are discharged via outlet 64.

[0072] Like the system shown in FIGS. 1 and 2 and in FIGS. 3 to 5 also the system shown in FIG. 6 operates continuous.

[0073] Furthermore, all systems shown in the drawings may be contained systems, for example with a containment level for product toxicity level OEB 3 or higher, measured for example according to the SMEPAC test.

LIST OF REFERENCE NUMERALS

[0074] 10 production machine [0075] 12 production machine housing [0076] 14 module housing [0077] 16 system housing [0078] 18 windows [0079] 20 outlet of product conveying device [0080] 22 product conveying device [0081] 24 inlet of product conveying device [0082] 26 first inlet [0083] 28 second inlet [0084] 30 third inlet [0085] 32 fourth inlet [0086] 34, 36, 38, 40 feeding and dosing devices [0087] 42, 44, 46, 48 refill systems [0088] 50 mixing device [0089] 52 first inlet of mixing device [0090] 54 second inlet of mixing device [0091] 56 outlet of mixing device [0092] 58 feed frame inlet of production machine [0093] 60 feed frame of production machine [0094] 62 vertical tube [0095] 64 outlet of production machine [0096] 66 doors [0097] 68 inlet hopper [0098] 69 outlet hopper [0099] 70 product conveying hose [0100] 72 conical diameter reduction [0101] 74 vacuum hose [0102] 76 vacuum generation device [0103] 78 tube with vent opening [0104] 80 dust extraction shroud [0105] 82 dust extraction hose [0106] 84, 86, 88 housings for technical components [0107] 90 rear wall