Coperion K-Tron Proud Supplier of High Accuracy Batch Feeders to Pfizer Germany High Containment Facility

This completely automated production facility is designed to maximize the efficiency and productivity of Pfizer's pharmaceutical production processes, doubling drug production capacity while shortening production times. 

The integration of Coperion K-Tron feeders into Pfizer's German facility underscores the pharmaceutical giant's commitment to leveraging cutting-edge technology to optimize its operations. This collaboration also demonstrates the growing importance of precise and reliable products in the pharmaceutical industry - characteristics that make Coperion K-Tron equipment stand out.

The state-of-the-art facility in Freiburg, Germany, houses over 2000 employees and has been built to supply tablets and capsules to over 185 countries. Current production includes 6.7 billion tablets and capsules annually. In addition, since the facility has the capability to handle highly potent OEB 4 compounds, all systems are completely enclosed and utilize split butterfly valve containment and drum dumping glove boxes for contained product transfer. 

In this groundbreaking automated process, a variety of raw materials — including excipients and active pharmaceutical ingredients (APIs)—are delivered to the automated dispensing systems via drums, big bags or smaller bags and are then introduced to the Coperion K-Tron high accuracy K3 line of pharmaceutical feeders. The feeders then dose the specified amounts required for the batch as dictated by the specific formulation through an overall PLC based control system. All batch setpoints are communicated directly to each KCM feeder controller, which in turn controls the high accuracy loss-in-weight (LIW) batching of the feeder. This initial batch is then mixed and moved to another station where more LIW feeders accurately dose additives into the batch, before the mixture continues to the tablet press.

The Coperion K-Tron line of K3-PH feeders has been specifically designed to meet the growing demands of continuous and batch processing in the pharmaceutical industry. Due to the use of a smaller D4 platform scale, incorporating the highly accurate Smart Force Transducer (SFT) weighing technology, these feeders require significantly less floor space than previous models. The feeder’s modular quick change design allows the easy exchange of feeder sizes, using the same scale and drive for fast adaptation to new processes and formulations while also ensuring easy cleaning and maintenance. The quick change feeder bowl, agitator, and screw combinations can be quickly decoupled from the feeder drive, allowing for simple and fast changeover and cleaning of the feeders. The updated modular concept features a newly developed drive using a servo motor which helps reduce the overall footprint and offers a much larger turndown range, including low feed rates. For an optimal wash-in-place result, every unit has an integral 2-degree pitch, facilitating maximum drainage during the cleaning processes.

High Precision Batch Accuracy with the New KCM-III Controller

The KCM-III features a completely new, powerful CPU with extended memory and optimized control algorithms to ensure faster communication with the feeder drive, weighing system and peripherals. In combination with the latest generation of Smart Force Transducer (SFT) load cells, the KCM-III also offers a significantly higher weighing resolution of 8,000,000:1 in 20 ms. The latest generation of SFT load cells allow for even higher sampling rates at 450 samples per second. These higher rates result in better noise filtering as well as less weight shift under vibration. In addition, the optimized controls lead to better short-term feeding accuracy as the control system reacts quickly to changes in the system. In the pharmaceutical continuous manufacturing world, where traceability is becoming more and more important, the KCM-III automatically stores up to seven days of log and event files, as well as trace and process data. 

The advanced and state-of-the-art automated batch dispensing system at this manufacturing facility in Freiburg will most certainly help to advance the production of groundbreaking medicines for a variety of applications. Coperion K-Tron’s complete line of equipment is engineered to meet the rigid requirements of the industry, including strict adherence to cGMP guidelines and standards as well as the use of FDA approved materials of construction.