Efficient Drying of IBCs at GSK with Secomak’s 9kW HeatPack

Introduction

GSK, a global leader in pharmaceuticals, faced challenges in efficiently drying Intermediate Bulk Containers (IBCs) after washing. The manual drying process was time-consuming and labour-intensive. To streamline operations, GSK partnered with Secomak to implement an automated drying solution using Secomak’s advanced 9kW HeatPack systems. This case study examines the benefits and improvements achieved through this collaboration.

Background

GSK had previously used a Secomak Heatpack at their Worthing site, which had operated without interruption for over 20 years. This reliability and performance set a high standard, prompting a return to Secomak for their new investment.

The Challenge

GSK’s existing process for drying IBCs involved manual labour, with operators hand-drying each container. This method was not only inefficient but also inconsistent, leading to potential quality issues. GSK required a solution that could:

1. Reduce Drying Time: Accelerate the drying process to enhance productivity.
2. Ensure Consistent Results: Achieve uniform drying to maintain high-quality standards.
3. Automate Operations: Minimise manual intervention to save time and labour costs.

The Solution

Secomak provided two 9kW HeatPack units, specifically designed to meet the rigorous demands of pharmaceutical applications. The HeatPacks included advanced control systems, featuring:

• Lockable HMI: A user-friendly interface that can be locked to prevent unauthorised adjustments.
• Heat Trend Lines: Real-time monitoring of temperature trends to ensure optimal drying conditions.
• Temperature Cut-Outs: Adjustable over and under temperature cut-outs to prevent overheating or underheating.
• Alarm History: A recorded history of alarms for troubleshooting and maintaining operational efficiency.

These features provided GSK with a reliable and efficient drying solution, transforming their IBC drying process.

Accurate Temperature Control and Efficiency

One of the standout features of Secomak’s 9kW HeatPack is its ability to accurately control temperature to within 1%. This precise control is crucial for maintaining the integrity and quality of pharmaceutical products. The HeatPacks utilise Secomak manufactured heaters and blowers, ensuring high performance and efficiency. These components are designed to deliver maximum heat output with minimal energy consumption, making the system extremely efficient and cost-effective.

Implementation

The implementation process involved:

1. Installation: Integrating the two 9kW HeatPack units into GSK’s existing workflow with minimal disruption.
2. Training: Providing comprehensive training for operators on using the new systems effectively.
3. Optimisation: Fine-tuning the systems to achieve the best drying performance tailored to specific needs.

Our commitment to customer service was evident with engineering support included for the installation, commissioning, and training of the operational team. This hands-on approach ensured a smooth transition and immediate operational benefits.

Results

The introduction of Secomak’s 9kW HeatPacks brought significant improvements to GSK’s operations:

• Time Savings: The automated system reduced the drying time of IBCs from several hours to just 5 minutes, greatly enhancing productivity.
• Labour Savings: By eliminating the need for manual drying, our customer was able to reallocate labour resources to more critical tasks.
• Consistent Drying: The advanced controls ensured each IBC was dried uniformly, maintaining high-quality standards.
• Operational Efficiency: The recorded history of alarms and real-time monitoring allowed for proactive maintenance and reduced downtime.

Financial Analysis

The investment in Secomak’s 9kW HeatPacks yielded substantial financial benefits for GSK:

• Labor Cost Reduction: Significant savings from reallocated manual labour.
• Increased Throughput: Faster drying times allowed for more batches to be processed, increasing overall production capacity.
• Quality Assurance: Consistent drying reduced the risk of quality issues, leading to fewer rejects and reworks.

Customer Satisfaction

GSK expressed high satisfaction with Secomak’s customer service. The proactive approach, including on-site visits to the Worthing facility for installation, commissioning, and comprehensive training, was greatly appreciated. This level of service ensured that GSK’s team could confidently operate and maintain the new systems, maximising the benefits of the HeatPacks.

Conclusion

The implementation of Secomak’s 9kW HeatPacks at GSK exemplifies how advanced industrial heating solutions can transform pharmaceutical manufacturing processes. By automating the drying of IBCs, GSK achieved time and labour savings while ensuring consistent and reliable drying performance. The precise temperature control and efficiency of the HeatPacks, combined with our commitment to customer service, underlined the success of this project.

The decision to invest in two new Heatpacks was part of a multimillion-pound investment at the Worthing site, reinforcing GSK’s commitment to leveraging reliable and innovative solutions for operational excellence. This case study highlights the potential for significant operational improvements and cost savings through the use of advanced heating technologies, positioning Secomak as a trusted partner in enhancing industrial processes.