Post on 21-Dec-2015
ILC Dover BackgroundILC Dover Background
ILC offers containment solutions for processing active pharmaceutical products Effective and safe systems get products to
market faster
Containment products include DoverPac ® Continuous Liner DoverPac ® SF
Pharm / Biopharm Products
Current Sealing TechniquesCurrent Sealing Techniques Twist-tie-tape and cut
Crimping
Thermal welding Senior Design focus
Why the high cost?Why the high cost? Film welder needs to be “explosion-proof” due to its
surroundings Design must meet several requirements for
approval Electrical requirements are main hurdle
Regulatory agencies involved NFPA
Class 1, Class 2, Division 1 Articles 496, 497
ATEX Ensuring the machine is explosion-proof is very
expensive!
Project ObjectiveProject Objective To design a film welder that can successfully seal
plastic layers together in an explosive environment without using electricity Eliminate electrical system approval hurdles Reduce cost
Produce an engineering model of the film welder Model must meet all performance specifications
possible Concentration on non-electrical aspect
Project ScopeProject Scope
Customer SpecificationsCustomer Specifications
Sealing temperature goal
130°C (266°F)
Sealing pressure goal 20psi ± 5psiCost per use $3Exterior temperature 50°C (120°F)Operators required 1Full sealing cycle time
2 minutes*
Sealing area 37” x 1.5” (23” Ø bag)
Metric Target Value
Be safe for the user Meet NFPA and ATEX regulations Use no electricity!
Constraints
*This target value was increased to around 5 minutes.
Steps to Complete CycleSteps to Complete Cycle
Start
Flush with H2O
Remove sealed plastic
Add chemicals
Insert plastic
Apply pressure
Concept SubsystemsConcept Subsystems
Heating & Cooling System
Pressure System
Heat Generati
on System
Thermal Sealer Prototype
Heat Generation SystemHeat Generation SystemThe system requires… Ability to reach temperature of 130°C as
quickly as possible Safe chemical components
ConceptsConcepts
Heat Generation Concepts
Epoxy Resin
Hydrogen Peroxide (H2O2) Decomposition
HH22OO22 DecompositionDecomposition TestingTesting
Mixed H2O2 and MnO2 in… An open beaker
Maximum temperature was 90°C A pressurized copper pipe
Maximum temperature was 144°C
Temperature goal cannot be reached if not pressurized
Amount of MnO2 only affects speed of reaction, not the temperature the mixture can reach
Lessons Learned…Lessons Learned…
Heating & Cooling Heating & Cooling SystemSystem
The system requires… Efficient heat transfer (for heating and cooling) Insulation to ensure cool outer surface User-friendly chemical addition system Effective drainage
Heating & Cooling Concepts
Hollow Al chamber
Eliminated copper tube “middle man”
Increased heat transfer efficiency
Heating & Cooling System Heating & Cooling System AnalysisAnalysis
Internal pressure analysis Need pressure valve that releases
between 150psi and 200psi
Force analysis Found deflection of steel casing
Adjusted thickness to minimize it
Aluminum end-cap (green)
Aluminum channel (grey)
H2O2 / H20 input valve
Pressure relief valve
MnO2 input valve
Draining valve (on bottom)
Progressive AssemblyProgressive Assembly Step 1Step 1
Air valve
Pressure SystemPressure SystemThe system requires… Even pressure application along length Ability to impose a tear strip on plastic Withstanding pressure from inflated bladder
Pressure Concepts
Inflatable bladder
Lever & lock
Turn screw
Pressure System Pressure System AnalysisAnalysis
Force analysis Found deflection of steel backing
Adjusted thickness to minimize it
Found force on the locking pin Determined the required diameter needed
Pressure AssemblyPressure AssemblyStep 1Step 1
Interior guide blocks (red)
Steel backing
(turquoise)
Steel casing (blue)
Step 2Step 2
Pressure plate (green)
Exterior guide blocks (red)
Force pad
(blue)
Tear strip O-ring (pink)
Pressure bladder (grey)
START
Steps to Add ChemicalsSteps to Add Chemicals
Open MnO2 valve
Add 1g of MnO2
Open H2O2 valve
Add 250mL of H2O2
Close MnO2 valve
Close H2O2 valve
Film Welder in ActionFilm Welder in Action
Setup
Pressurize
Add chemicals
Flush system with water
Depressurize
Remove sealed plastic
Heating & cooling system Validate:
Time to seal Sealing temperature goal Sealing area Exterior temperature
Pressure system Validate:
Sealing pressure goal Even pressure distribution
Test entire prototype Validate:
One operator required
Cost per use
System ValidationSystem Validation
Heating Arm TestingHeating Arm Testing
Heating Arm Testing Isolated heating arm
Varied chemical amounts 150-250mL H2O2 0.5-1.0g MnO2
Varied chamber pressure 60-200psi
Varied MnO2 input valve location
Temperature Validation Results
0
20
40
60
80
100
120
140
0 2 4 6 8 10 12 14 16
TrialT
emp
erat
ure
(°C
)
Target Value
Testing Results
Trial 1-6: 150mL H2O2, 0.5g MnO2
Trial 7-15: 250mL H2O2, 1g MnO2
Results and ValidationResults and Validation Results
Temperature peak is very inconsistent Target value for temperature was not met
but plastic did seal Average time to seal was 2 minutes, 24
seconds
Validation– Time to seal 2 minutes, 24 seconds– Sealing temperature goal 127°C– Sealing area 14” x 1.5”– Exterior temperature 25°C
Pressure Arm TestingPressure Arm Testing Pressure Arm Testing Isolated pressure arm
Inflated bladder with air pump Used Pressurex® pressure sensing film
Trial 1
Trial 2
Results and ValidationResults and Validation Results
Very even pressure distribution across length Across o-ring, pressure was about 75psi Elsewhere, pressure was less than 28psi
Tear strip was imposed
Validation– Sealing pressure goal < 28psi– Even pressure distribution Yes
Target vs. Actual ValuesTarget vs. Actual Values
Sealing temperature goal
130°C (266°F)
127°C (°F)
Sealing pressure goal 20psi ± 5psi < 28psi
Cost per use $3 ≈ $4
Exterior temperature 50°C (120°F) 25°C (77°F)
Operators required 1 1
Full sealing cycle time
5 minutes ≈ 5 minutes
Sealing area 37” x 1.5” 14” x 1.5”
Metric Target Value
Actual Value
Handoff to ILCHandoff to ILC
Sealing can be accomplished using non-electrical means Hydrogen peroxide decomposition is one
successful method Purchase a more accurate pressure
relief valve Further work needs to be done in order
to transfer product to industry Patent potential after further investigation
and testing
AcknowledgmentsAcknowledgments
Sponsor• ILC Dover
– Dave Cadogan and Anshu Dixita
Advisor• Dr. Keefe
Technical Advisors• Dr. Wingrave (Chemistry Department)• Steve Beard (Machine Shop)• Dave Styer (Machine Shop)
• Heat transfer analysis– Found temperature of 133°C is required to
ensure full heat conduction through plastic
• Thermodynamics– Found 180mL of H2O2 is needed to get
reaction to 133°C
Heat Generation AnalysisHeat Generation Analysis
T1=133°C
T2=130°C Input heat
Pressure System BudgetSteel (backing, end-caps, arms) $190
Aluminum (U-channel) $33
Schraeder valve $2
O-ring $3
Force distribution pad $37
Total System Cost $265
*ILC has agreed to take care of making the inflatable bladder.