ANDOCKSYSTEME G. UNTCH GMBH

EVOLUTION IN CONTAINED PACKAGING

ACUBE is an integrated single-use containment system that typifies a clever and purposive further development of a flexible packaging unit. It complies with all customer needs relating to primary packaging as well as tertiary packaging.

Composed of two independent liner systems it stands for flexibility and robustness. The inner liner acts as product bag to protect the product from environmental impacts and vice versa. The outer liner is the reinforced protective layer that withstands mechanical stress. Because of this multiple liner construction the system is allows manual support of poor flowing product by tumbling.

Equipped with the outstanding AVAX technology it allows various material handling operations under fully contained conditions. ACUBE is available from 10L up to 400L and covers all aspects of powder, granule or tablet handling.

As an option ACUBE can be delivered as an approved execution suitable for ATEX zone 1. Thanks to its cubic 3D shape complete emptying is even under non-atmospheric conditions like downstream of a tablet press (slight negative pressure) easily to realize.

In conjunction with a transport box made from cardboard ACUBE is appropriate for transportation from one facility to another. UN transportation certificate is available.

• Integral containment system
• Flexible but robust
• Easy emptying of poor flowing products
• Operation under non-atmospheric conditions
• Primary and tertiary packaging
• Conductive execution available

VALVES FOR HIGHEST REQUIREMENTS

AVAX is the trend-setting and unrivalled split butterfly valve technology from Andocksysteme. Completely made of medical-grade plastic materials it represents the origin for a new generation of single-use containment interfaces.

Strictly designed as a congruent passive to passive system, this unique valve enables its usability in any desirable application due to its interoperability.

• Meets OEB 5 requirements (STTW ≤ 1 mcg/m³)
• Intuitive and secure handling
• Tri-Clamp seal integrated (4” BS 4825-3)
• Hybrid operation with stainless steel AVAX optional
• Sterile execution available

Key technology of AVAX is the implementation of an established locking mechanism – the bayonet coupling. By this technical evolution it is the first time that housings and discs are locked to each other individually but by a mutual locking motion.

As a result of two-component injection moulding manufacturing process, fully hygienic design is guaranteed. The seal material is incorporated by chemical bonding forces which gives seamless results. All system components comply with the major pharmaceutical requirements like FDA, USP and EP.


The revolutionary new AVAX split butterfly valve technology is also available in stainless steel. This allows AVAX to be used for applications with higher pressure and or temperature requirements.

Moreover it can be operated as a multi-cycle device like the market-leading Andocksysteme SBVs. Due to its complementary passive to passive design it is fully compatible with the single-use version. A hybrid operation like stainless steel and plastic valves is integrated standard.

The system can be operated either manually or automated by use of a retrofitted actuated opening device.

ONE FITS ALL

ACLAMP - Andocksysteme CLAMP is a trailblazing development in flange fastening. This advantageous device, which consists of just two pieces, clamps multiple size ferrules. It is the first and the only true disposable system on the market.

Derived from the simple but proven principle of a cable tie it allows the secure and quick connection of various flanges and joints. The impressive ACLAMP innovation can be easily customized by the operator.

ACLAMPs elementary advantages:

• Flexibility and variability
• Intuitive and convenient handling
• Adjustable and reproducible clamping force
• Safe and non-detachable connection
• Low cost single-use system

The ACLAMP all-rounder is the perfect solution to attach any kind of single use equipment to each other.

Moreover the extremely stable and fittable ACLAMP is suitable for the purpose with stainless steel devices or in hybrid set-ups. These could be connectors, tubes, bags and liners or even process equipment like valves, sensors, bins and reactor vessels.

VALVES FOR HIGHEST REQUIREMENTS

The Andocksysteme Containment Split Butterfly Valve - ASBV - consists of an active and a passive valve that are supported on two sides by high-grade precision bearings. The passive valve can be mounted on the inlet and/or outlet of an IBC.

The active valve is operated either manually or automatically, is integrated into the filling or discharging side of the process station, and can be equipped with a diversity of options. When docking, the GMP designed locking pins centre the active and passive valve on to each other. Both butterfly halves open simultaneously after docking. During filling and discharging the product is fully contained under perfect conditions.

The docking process can be achieved either with a mobile container using a lifting column, or automatically with lifting cylinders mounted directly on to the active valve. After undocking, the active valve will return to its centred position.  When re-docking, the active valve will pinpoint the passive valve with an accuracy of ±14 mm.
 
Whether Alloy 59, HC 22, coatings, or special light weight materials for non-product contacting parts to save weight, seal materials in EPDM, VITON, Perfluoroelastomer or PTFE – everything is possible. It’s only a matter of requirements.

The ASBV is much easier and more convenient to operate, the positioning of the passive valve on to the active valve is 180° turnable.

Automation is not always needed. Sometimes, less is more. Manual valves are easy to operate and do not need controls. An active valve can be made into a passive valve, or an automatic active valve can be made into a manual valve simply by eliminating or replacing a few parts. That means: a minor refit resulting in shorter downtimes without additional spare parts.

For simple and easy cleaning of the valves, it is often sufficient to rotate the valve halves outwards by 180°, both of the active and the passive valve. Before dismantling, the docking system can be mounted with a CIP dome having a static or rotating CIP nozzle to bind the dust particles to prevent dust from escaping. In most cases, the parts to be cleaned (active valve with bellows) are removed from the process station using a suction pad without the need to disconnect the hoses and cables from the actuators or controls. With the need for ever-shorter downtimes, production can be resumed after five minutes simply by installing another active valve. This saves time and money - an unbeatable advantage.

VALVES FOR HIGHEST REQUIREMENTS

Each enquiry is a challenge. When things are seen as a challenge, then full attention will be devoted to it. Processing is a difficult area. However, for a Segment Ball Valve, it is a solved case.
Expertise and a high level of professional competence, individual advice and good engineering, customer’s orientation and last but not least, perfect performance, are the basic fundamentals of these valves for the highest requirements.

A Segment Ball Valve consists of a housing and a segment of a ball that is supported on two sides by maintenance-free bearings and sealed with an inflatable seal. A 90° rotation of the segment allows even difficult flowing products to pass the valve’s full bore in a short amount of time. During the rotation, the segment moves freely past the spherically shaped housing.
A Segment Ball Valve can be used both as an inlet and an outlet valve and can be used to shut a stream of flowing product.

All Segment Ball Valves are manufactured individually. The application of a Segment Ball Valve in dryers and blenders can also result in a system with a minimum of dead space. This will not only increase the product quality but also guarantee a continuous high-grade process.
 
The most commonly used applications in which the Segment Ball Valves are applied are:  Conical blenders, mixers and dryers, reactors, double conical dryers, horizontal blenders and dryers, agitator vessels, sluices and in piping.

High-level equipment with High-tech components.
A few characteristics that the Segment Ball Valve distinguishes itself from other valves are: High-grade seals;  vacuum and pressure tight;  full bore without any restrictions;  a long service life, even at high and low temperatures;  CIP;  no dead space in product contacted areas and a high demand of quality for product contacted surfaces. The valves can be applied from liquids, pastes to solid products and are vacuum and pressure tight in both directions.

Compared to others, the Segment Ball Valve stands out because of the high quality and the perfect sealing system, that allows the valve to function up to a pressure of 10 bar. This is made possible because of the inflatable EPDM, FKM (VITON) and FFKM Perfluoroelastomer- Seals, which are compliant to the FDA regulations. The Segment Ball Valve is operated by a pneumatic actuator, which is controlled by an integrated control unit. This control unit regulates the inflation sequences of the seal.
An optional positioner can also be utilized to allow the Segment Ball Valve to operate as a dosing valve.

Added convenience - CIP technology
It doesn’t get any simpler than this. A Segment Ball Valve can be supplied with a number of CIP nozzles or retractable CIP lances, so that the valve doesn’t have to be disassembled for cleaning The GMP design guarantees a reliable cleaning process.

Vertical dryer equipped with a Segment Ball Valve as an outlet valve
In areas where high requirements are demanded in a production process, Segment Ball Valves are being used to enhance and shorten production processes.  The valve’s main qualities are especially apparent when a high quality Segment Ball Valve is in combination with a vacuum dryer.  This combination will give an outstanding drying result that is realized due to the valve’s excellent vacuum tightness.
During discharge, opening and closing of the valve, the inflatable seal is completely protected from the product flow and moving segment, therefore minimizing seal abrasion.  
Whether for the pharmaceutical, chemical or food industry, the Segment Ball Valve is commonly utilized in these fields because of its durability and long service life.
The Segment Ball Valve is also attractive for the “revamp / overhaul market” because each valve is customized to meet individual specifications.

Examples of the advantages that distinguish these valves from others, to give our customers something they can refer to, are:  Coatings and special material grades, such as HC 22, Alloy 59 or Titan; Nitrogen purge flanges used for faster drying processes, or used to drain liquids;  cooled or heated segments or valve housings;  insulated valves;  integrated sight glasses for inspection purposes;  special actuators;  controls with integrated fail-safe technology;  actuator assemblies at different levels.

The existing, we will improve. What doesn’t exist, we will design from scratch.

Applications:
• Sampling of powders, granulates and liquids from vessels and reactors without disturbing the process
• Adaptable to conical, horizontal and flat bottom mixers, dryers and reactors
• Mainly for the chemical, pharmaceutical and food industry

Key features:
• Based on the “segment ball valve” principle meaning sanitary GMP design and therefore easy to clean
• Samples can be taken while vessel is pressurized up to 10 bar
• Automatic depressurizing of the sample bottle for operator safety
• Very accurate sampling volumes can be taken, especially when compared to piston type sampling valves
• Main seal is exchangeable without having to disassemble the valve from the system - resulting in reduced down time
• Quick connect CIP system with integrated drain connection
• All seals are O-rings therefore low spare parts cost

General technical data:
Bore: Sample bore: variable between 0 and 50 mm
Flanges: Special block flange
Pressure: Full Vacuum and pressure up to 10 Bar
Temperature: -20 /+280°C (depending on seal material)
Materials: Standard 1.4404/316L
Seal: O-ring seal e.g. EPDM, FKM (Viton) or FFKM Perfluoroelastomer (all FDA approved)
Finish: Product contacting parts Ra<0.8 μm, outside surface machined finish (others on request)

Manufacturing standards:
PED 97/23/EC, ATEX compliant, CE marked

Options:
• Automated sampling
• Mechanically locked sampling bottle for enhanced safety on pressurized systems (“foolproof”)
• Spring return lever to prevent the valve from being opened unintentionally
• Proximity switches for closed detection and/or sampling bottle in place
• “Clean In Place” - Quick connect CIP system with integrated drain connection
• Monitoring and detection of main seal leakage
• Additional split-butterfly technology for taking contained product samples
• Mirror polished finish on wetted parts
• Special alloys (e.g. Duplex, Alloy C22 etc.)
• Fully customizable according to customer requests

Flexible, robust and FDA compliant.

Our compensators provide the flexibility to eliminate misalignment issues or provide connections to process equipment with strict weighing requirements.  With this in mind the manufacturing of compensators and bellows are maintained to the highest requirements and highest quality.

Compensators and bellows are mainly used for the final connection between transfer chutes and process equipment.

We have a complete range of injection mould tooling for the manufacture of different lengths and thicknesses of compensator and bellows. Confidence that the internal diameters of the compensator and the process chutes / equipment match, eliminates the occurrence of crevices or ledges which ensures effective WIP/CIP without disassembling.

The material hardness is between 30 and 75 Shore. Our product range spans from DN100 to DN300 conforming to DIN 32676 up to DN200 and BS4825 up to DN300.  Compensators and bellows come as standard in FDA compliant white and black EPDM and Viton.  FDA approved Silicone can be supplied on request or for particularly aggressive duties FFKM or FFPM elastomers are available.

Conductive black compensators and bellows can also be supplied for process requirements in EX-zones which are also FDA compliant. All the bellows and compensators are normally fitted with a bellow flange. This can be connected directly to the customer’s flange or to a TRI-Clamp adapter. For further details please refer to the drawing and table.

Bellows with a 1mm wall thickness can be supplied for critical weighing applications which require the weigh cells to be sufficiently isolated from adverse process forces.  This ensures maximum flexibility, minimum interference on the weighing process and containment guaranteed.

Bellows and compensators are available in a range of lengths, diameters and thicknesses to suit all applications and are capable of filtering out unwanted movements and vibrations in both axial and lateral directions.