Solving aging-equipment challenges at once| Engineering away rust risk and human error

The equipment we had been using for many years had become significantly worn. After we requested parts replacement, we decided it was time to renew the equipment.

We use purified water as a raw material, but with the existing tank we were concerned about rust and its potential impact on product quality, which also caused anxiety during inspections.

In addition, we insert a glass-ball filter (a glass component used in the bubbling system to increase dissolved oxygen) inside the tank. When we used the agitator, there were cases where the filter contacted the agitator, creating a breakage risk (about once in every 10 runs). This was a serious issue in terms of hygiene and raw material loss.

The biggest deciding factor was MONOVATE’s ability to propose a customized solution based on a solid understanding of our on-site issues.

Because we did not want to change the existing manufacturing process significantly, MONOVATE proposed a “brush-up” approach to improve the tank while preserving our current operation. We also appreciated the proposal to reduce the glass-ball filter breakage risk, including the agitator’s shape and positioning, and a dedicated hanger to support the filter.

Because we manufacture pharmaceuticals, hygiene is critically important. The new tank has an electrolytically polished interior, and we expect a significant improvement in corrosion resistance and cleanability compared with the existing tank.

Previously, the method of installing the glass-ball filter varied by operator. With the dedicated hanger, we can greatly reduce human error and proceed with daily manufacturing operations with greater confidence.

Through this project, we learned more about MONOVATE’s responsiveness and customization capability. We will continue renewing equipment in the future, and we would be glad to consult with MONOVATE again. Overall, we are very satisfied with the introduction of this tank.