PILOT EX

The solution for explosive areas
 

In the weighing and dosing room, everything must work together seamlessly: precise weighing, clean dosing, complete documentation and a workstation that can be thoroughly cleaned between batches. When processing powdered active ingredients, excipients, or solvent-containing substances, flammable dusts or vapors can be generated. In such cases, a conventional cleanroom workstation is no longer sufficient, as the hardware used must be suitable for the classification of the potentially explosive area. The PILOT EX was developed specifically to meet these requirements.

In wet granulation, the process must remain visible. Humidity, temperature, formulation status and system alerts should be available right where the work is being done: directly at the granulation line. When organic solvents such as ethanol are used, flammable vapors may form depending on the substance’s properties, concentration and room classification. In such cases, the cleanroom workstation must also comply with the applicable Ex-zone classification.

In API synthesis – the production of active pharmaceutical ingredients – a great deal of information converges directly at the reactor: process values, formulas, alarms, documentation and operational decisions made during the ongoing process. Especially when working with flammable solvents, the area surrounding the reactor may be classified as a potentially explosive atmosphere. In such cases, the operator interface and visualization technology used must also comply with this classification.

During tablet compression, grinding, or screening, dust is a common occurrence on the production line. Fine particles can settle or become airborne. Depending on the material properties, concentration and room classification, fine dust can be a factor in determining whether an area is classified as potentially explosive. In such cases, it is not enough to consider only the machine itself; the operator’s workstation must also be suitable for the production environment.

When filling alcohol-based liquid pharmaceuticals, high throughput isn’t the only factor that matters. Operators must quickly capture process data, clearly identify status messages and maintain a clear overview at all times – even as their perspective shifts along the filling line. At the same time, flammable carrier substances – depending on material properties, concentration and room classification – can form explosive mixtures of vapor and air. For example, ethanol has a flash point of about 13 °C. This illustrates why explosion protection plays a crucial role in the filling of alcohol-based products.