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The Genesis Sterilization/Depyrogenation Tunnel is a fully automated system that uses laminar flow air to sterilize glass vials. Tunnel is capable of rates up to 750 vpm, depending on the vial size and weight. The tunnel can be made to function as a stand-alone unit or in conjunction with a vial washing system.
Tunnel controls are housed in a separate main control panel and automated by an Allen-Bradley Programmable Logic Controller (PLC). A Kaye data logging unit records hard copy data derived from analog transmitters and thermocouples located throughout the tunnel.
Operationally, vials entering the tunnel are transported through the Preheat Zone where they are exposed to a flow of partially heated air. The preheat zone also prevents hot air from escaping to upstream equipment. The hot zone has heating elements that heat the air to various temperatures (up to 350§C), depending on the requirements of the operation protocol. Heat transfer is accomplished by hot air that is generated by a blower inside the Hot Zone. After the vials exit the hot zone, they are gradually cooled to about 25§C in the cooling zone. Both sides of the cooling zone are sealed off with gates. The entrance gate prevents larger amounts of air from entering the Hot Zone. The exit gate prevents excessive sterile air from flowing into the tunnel.
Patented Overpressure Bypass System allows relief of overpressure from fill room ensuring no interference with Hot Zone air flow. The cooling zone over-pressure damper is controlled by a differential pressure switch that measures the pressure differential between the cooling zone and the fill room. If the pressure difference between the cooling zone and the fill room reaches the switch setpoint, the over-pressure damper opens, allowing the cooling zone pressure to lower.
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