With the advent of steam sterilizer, we have succeeded in developing a bung processor system which can be washed, siliconized and sterilized and dried in one go without contaminating the bungs. This bungs can be directly used for further manufacturing activities in a sterile facility.

Processing of bungs is of high concern since they play a significant role in the quality and life of the final product.

The need for correct processing technology is even more important considering the complexities in the compounding of the rubber used for the closures.

The system has its own CIP facility for keeping the machine ready for new batch. Advance carriage design and drum design enables a smooth and easy operation for user.

Exclusive Features :

• Rotating carriage: A perforated carriage with view glass and designed in such way that percolation and cleaning of bungs from all sides has given us the confidence to overcome faulty process. There is no need of any cassettes, theses bungs will freely move inside the carriage for proper cleaning.
• Sprinkling manifold : The system is designed to provide proper mixture of water, detergent etc. in contact with the bungs through sprinkling manifold arrangement. This enables uniform sprinkling over the entire bungs.
• Fluidization manifold : Once the process starts the particulates settles in the bottom and this needs to be taken out from the chamber. This is done by providing air nozzles at the bottom of the chamber. Air is passed at high pressure in the system to form heavy froth. This froth carries the particles and dirt’s to the top surface of the water inside the chamber. At the middle level of chamber there is a drain connection which allows dirt to go out. This causes effective cleaning of system.
• Sampling system in the drain : during the stage of final rinse with WFI, the integrity of system can be checked online by a Conductivity sensor which ensure Proper washing of the bung.
• Clean In Place system (CIP) : The BUNG PROCESSOR has inbuilt Clean In Place (CIP) system for washing the chamber and the rotating carriage to prevent the dirt or debris to be carried out from one cycle to another. This is very important before the start of the "Rinse with purified water" and "Sterilization" phases.
• Drive System :The mechanism of drive system has to ensure zero leakage from drive connections and ensure minimum friction between contact parts. Specially developed gears are used to ensures no particle generation during the process and allows the absence of any lubrication. A special non-lubricated mechanical seal is used for pressure and vacuum tight operation of the driving system.
• Dual Operation : The Bung Processor is designed for dual operation. It means if you are looking for only sterilization of media and garments, then we can choose the appropriate option apart from bung processing this has saved additional space and investment cost at customer end.

Process For Bung Washing Programs :

• The Process of bung processing are loading, washing with detergent, D.M. water & W.F.I. rinsing, siliconization , sterilization and drying.
• Washing - The loaded bungs are washed with detergent solution via a fully automatic detergent dozing system to remove the particulates, dirts, debris from the bungs.
• Rinsing -The washed bungs are rinsed with deionized water and WFI water and the quality of WFI water at outlet is checked automatically to ensure the proper washing of the bungs.
• Siliconization - After cleaning closures are siliconized using a silicone emulsion or oil. Siliconization of closures is necessary to prevent the release of plasticizers and other compound added during the process, to prevent any reaction between the closure and the medication stored or to ensure smooth operation of the machines used for bunging.
• Sterilization - In Sterilization the closures are sterilized with steam. A pre-vaccum process is employed to ensure effective removal of air and penetration of steam.
• Drying - After sterilization the closures are dried using a vaccum drying process. The drying efficiency is further improved by the continuous rotation of the closures.

We make sure that the products that we deliver will remain completely damage free as we make use of the quality packaging material and have skilled personnel for the packing of the products. You can choose to make payment through offline and online mediums as per your convenience. We are well versed with all and we ensure that the transaction is transparent.

 

Details :

• Capacity range - 5 Kg to 10000 Kg.
• Equipments Provided - Manufacturing Vessel.
• Agitator with scrapper assembly for manufacturing vessel.
• Top entry/Bottom entry/Inline Homogenizer for manufacturing vessel.
• Lobe Pump.
• Vacuum Pump.
• Water Phase Vessel.
• Bottom/top entry mechanical stirrer for water phase vessel.
• Wax Phase Vessel.
• Bottom/top entry mechanical stirrer for wax phase vessel
• Interconnecting Pipelines.
• Manual/Pneumatic Butterfly valves.
• Conical Filter.
• Manual/ Electro-Pneumatic control panel.

In order to recover the clean condensed water and enable its reuse from the RO rejects and ETP solution we offer Multi effect evaporators.
 
The system is used to reduce the water loss through double or triple Effect Combination Evaporator with one falling film type and one forced circulation type evaporators. The material of construction for all liquid contact parts in SS304 and Calandria tubes of SS304. All vapor and condensate contact parts will be in M.S.

Complete system will be under pressure at 3 kg/cm2( g).and consists of following components :

• Feed Pump : A centrifugal direct driven pump is used for transferring the feed solution from the balance tank to the Calandria. The pump is provided with a single mechanical seal and electrical motor. All contact parts with liquid will be in S.S.304.
• Calandria  : This Calandria is essentially a vertical shell and tube type vertical heat exchanger and is designed as per the Falling film /forced circulation principle. Steam is provided on the shell side and feed solutions is passed through tubes. The tubes of Calandria are of 25.4/ 31.75 mm OD. Adequate no. of tubes 4/6 M length are provided for the heat transfer duty.  The tubes are welded on the tube sheet.  The shell has nozzles for steam/vapor inlet and outlet, and temperature gauge. All Contact parts with liquid will be in S.S.304. Tubes will be of S.S.304. Thermic fluid/Steam and other non-contact parts will be in M.S.
• Vapor Separator : In vapor separator, the heated liquid coming from the Calandria is flashed. Saturated vapors coming out from top are sent to the next Calandria/condenser. Liquid concentrate coming out from bottom is withdrawn as feed to next Calandria/ as product. The separator shell has sight and light glass for viewing the concentrate level. Material of construction for all contact parts with liquid and vapor will be S.S.304 and non-contact parts will be in M.S.
• Re-circulation Pump : This pump is provided for re-circulation of slurry inside the heat exchanger, so as to increase the velocity of liquid inside the tubes and to get the required heat transfer. This is a Centrifugal Pump with double mechanical seal and motor. Contact parts will be in S.S.304. Concentrate outlet will be taken out from recirculation pump so the discharge head will be at around 5-6 meter only.

Condenser is used to condense the evaporation rate at the outlet of system. It also consist of condensate pot, condensate pump and vacuum pump.

Multi Column Distillation Plant is based on FINN-AQUA design. It consist of specially designed columns which make optimum use of the principles of inter stage heat exchange (Multi effect distillation method) to produce pure pyrogen free sterile distilled water for injectable as per IP/BP specification. The vapor with high velocity and under pressure passes over a SPECIALLY DESIGNED SPIRAL BAFFLE system which develops tremendous centrifugal force and thus eliminates any chances of pyrogens carry over in the vapors.

To industries where 100% pure Pyrogen - free water-for injection plays role, Multicolumn Distillation Plant is the perfect solution. Available in capacities ranging, the Multicolumn Distilled plant is used for its economy, low maintenance and low operation costs. By Multi Effect Distillation method significant energy (75% approx.) is saved when compared to the conventional method. All contact parts are made out of AISI 316 quality stainless steel and mirror polished. All pipes and tubes are essentially seamless.

Operation :
The pre-heated feed water (through condenser) is fed into the first column where 33% of feed water is converted into steam under pressure by outside boiler steam. The pure steam produced in the first column having temperature of 135 degree Celsius and the remaining feed water goes to the 2nd column. The pure steam is used as a heating media in the 2nd column and converts part of remaining feed water into steam. In the process the steam itself condenses back into water. This process is repeated till the last columns each working at low temperature & pressure as compared to the one before it. The steam produced in the last column is condensed in the condenser by feed water as well as cooling water. As external heat is required only to convert the 33% of feed water, the heating energy required is reduced by 67%.

Construction Details :

• Distillation column houses the heat exchanger & pyrogen separation system.
• Heat exchanger in first column with Double Tube Sheet Design as per USP requirement.
• Common condenser at the end of distillation process to condense steam & separate gas from distillate
• Vent on the condenser is with 0.2 micron bacteria retentive filter for safe shut down.
• All seamless pipe with orbital welding inspected by boroscopic procedure.
• Designing is as per ASME std. All surface finish better than 0.3 Ra.

Salient Feature :

• Total energy saving is 75% as less heating energy and less cooling water is required.
• Pyrogens are removed by centrifugal force developed & specially designed spiral baffle.
• All contact parts are s.s.316 quality. All pipes and tubes are seamless and gaskets made form teflon.
• Distillate Temperature is quite high.( 90-95')
• Distilled water as per IP/BP standards and conductivity less than 1 micron/cm.
• Online temp. monitoring of WFI
• Conductivity monitoring and control for feed water & WFI
• Automatic feed water control to prevent column flooding.

The Bung Processor has inbuilt Clean In Place (CIP) system for washing the chamber and the rotating carriage to prevent the dirt or debris to be carried out from one cycle to another. This is very important before the start of the "Rinse with purified water" and "Sterilization" phases.

 

CIP System Consists of :

• CIP Tank 50 Ltr to 5000 Ltr.
• CIP Skid with mobile trolley.
• Acid Carboy.
• Alkali Carboy.
• Acid Dosing Pump.
• Alkali Dosing Pump.
• Supply pump.
• Recirculation pump.
• Heat Exchanger if required.
• Air Vent Filter.
• Level Sensor.
• Pneumatic Diaphragm valves to control process.
• Steam trap.
• Temperature Sensor.
• pH sensor.
• Conductivity sensor.
• Control panel with PLC/HMI & Printer.

We are capable of catering to buyers anywhere in Thane(India) as well as any other place. We have resources to reach the buyers' Thane(India) with ease. Our company has a convenient and noncomplex payment procedure. Patrons can make payments through a method with they are comfortable. We are open to receiving payment online or offline.

 

Details :

• With confidence of highly experienced team, we have developed a series of autoclaves with 3rd generation technology including latest 21 CFR part 11 compliance system and self-steam creator and water recirculation technology.
• Gemerik has also been successful in achieving the temperature accuracy level upto 0.2 deg C probe to probe under sterilization condition with automatic control of steam input. Today Gemerik has its own segment of simplest, cheapest, and most flexible autoclave which makes us extra-ordinary solution providers.
• This High Vacuum Steam Sterilizer is used for sterilization of machine parts, change parts, fabric, tubing, bulk drugs, etc. in a pharmaceutical facility.
• Capacity range from 100 ltr to 8000 ltr.
• All contact parts in SS316L
• All connections are having Triclover end.
• Inbuilt vacuum system.
• All cycles run through PLC / HMI programs hence totally automatic and accurate.
• We provide complete documentation of system.

Customized option for steam sterilizer :

• Single door or double door
• Shelve mounted or carriage and trolley arrangement
• Inbuilt control panel or separate control panel
• Inbuilt steam generator or per steam operated

In order to keep our offerings in safe and secure conditions, we have developed a storage unit and keep it updated with the defined industry standards. We are a quality-centralized firm and make use of only high quality material for manufacturing the offered lot. Also, we ensure that the material is sourced from the reliable places.

 

Details :

• We offer Super-Heated Water Spray Sterilizer for LVP / SVP / IV Bags / Glass Bottles / Plastic Bottles / Pouches.
• The design is based on uniform forced water circulation in a closed loop system through Heat exchanger.
• The key feature of this system is over pressure counter balancing inside containers during sterilization avoiding and cracking / breaking leakage / deformation of PP bottles due to internal pressure developed by the liquid product.
• The Heat Exchanger is shell and tube design used for heating and cooling the water during sterilization process.

The Process :

• Water is heated upto 121degC in a heat exchanger and circulated in the chamber. Water acts as a sterilizing medium in a closed loop system. 
• The compressed air is purged in the chamber to maintain the chamber pressure equal to the container pressure throughout the process. This support pressure is  totally  controlled automatically by the P.L.C.
• Thus heating – hold – cooling sequence is carried out with precision on both the vital parameters like temperature and pressure.
• The system follows counterbalancing of overpressure formed inside the containers during sterilization, avoiding breakages and deformation.

The most important equipment in any Pharmaceutical Plant manufacturing injectable solutions is the Pure Steam Generation Plant. Gemerik has developed WFI Still which produces distillate that meets the current U.S. and European Pharmacopeia for Water for injection guidelines equipped with a range of features to ensure that your installation and qualification is quick & trouble –free and that your WFI production remains efficient and reliable throughout your unit’s life.

Gemerik PSG is designed with efficiency keeping in mind. Because the system recovers the latent heat of vaporization which occurs within its own process to heat feed water and uses the feed water as the primary source of cooling.

Gemerik uses Corrugated Tube Heat Exchanger which is a next generation of Shell & Tube Heat Exchanger. With this technology we can achieve High Pressure & High Temperature with Less Maintenance & leakages. As heat exchanger has the main role in determining the efficiency of Pure steam Generator, we have achieved Higher Heat Transfer Co-efficient, Compact and economical model with reduced Fouling and dense turbulent flow even at low velocity.

Key Features :

• Capacity range 50 to 1000 kg/h.
• External evaporator, ease of maintenance.
• Unique optimized separation method.
• Full PID level control for safe consistent performance.
• In-house design and manufacture, cGMP double tube sheet heat exchanger, ensuring high quality control and consistency.
• cGMP design and regulatory compliance.
• Degasser option to reduce non-condensable gases.
• Research is undergoing with use of Corrugated Tube Heat Exchanger which is a next generation of Shell & Tube Heat Exchanger.
• With this technology we can achieve High Pressure, High Temperature, Less Maintenance & leakages.
• As heat exchanger has the main role in determining the efficiency of PSG and WFI, we have achieved Higher Heat Transfer Co-efficient, Compact and economical, model with reduced Fouling and dense turbulent flow even at low velocity.

Features :

• Vessel is a Vertical cylindrical with flanged end main shell & flanged end top dish along with tori spherical bottom dish welded to main shell.
• Vessel has 45 mm puff insulation cladding to avoid Heating-cooling transfer losses.
• Manhole / hand holes are provided depending on vessel size for viewing and maintenance of vessel.
• Sight glass with lamp is view the process inside the vessel in closed conditions.
• Vessel is provided with castor wheels or mobile skid to enable easy movement.
• Vessel is jacketed with steam / cooling water inlet / outlet facility to maintain the product temperature inside the vessel.
• For weight indication of product Load cell is provided.
• Various sensors are provided for process control like temperature sensors, level sensor, PH sensor, Conductivity sensor.
• Vessel is connected to CIP & SIP system for cleaning & sterilization purpose. To fulfill CIP & SIP purpose we provide a spray ball along with Manual Operated diaphragm valve.
• Control panel & vessel are provided on same skid.
• Design code is confirmed to ASME SEC VIII, DIV-I, Non IBR Pressure Vessels & BPE STD 2008.
• Vessel capacity Range from 3 ltr to 10000ltr
• Vessel Material of contact parts is SS316L and other parts are of SS304.
• Vessel are internally electro polished.
• All accessories like Load cell, Vent filter, spray ball, light glass, hand hole, ZDL valve, diaphragm valves, magnetic stirrer etc. are purchased from reputed makes.

We have well-connected and capacious warehouse that helps us in arranging products systematically to deal with urgent deliveries and orders. Our exceptionally good warehouse system helps us in keeping the products safe till the final dispatch. Buyers can place bulk or retail orders with us all year round and expect on time delivery of consignments.

 

Storage Tanks :

• WFI Storage tanks ranging from 1000 L – 25KL.
• PW/ RO/DM Water Storage Tanks (1000 L – 25KL)
• PW/WFI Skid with piping, looping & Distribution.
• Sterile & Aseptic Process Pipe Line Site activity.

Timely delivery of the orders is assured with us as we are backed by one of the most sophisticated transportation facility. Stay rest assured for the products that we offer as they will remain damage free. For this, we make use of only premium packaging material for the packing of the products.

 

Details :

• DHS uses dry air, hot air as  a sterilisation / de- pyrogneation medium at a  temperature of upto 250 dge C.
• Capacity Range From 160 to 2000 ltrs volume

Salient Features :

• Complies with requirements of HTM2010 and US FDA.
• Stainless steel construction with hydgenic design.
• Class 100opertation for maximum sterile integrity of the product.
• User friendly, automatic operation with on-line process doucmentation.
• In-built  ports for validation and perfomance qualification.
• Comprehensive safety features for  best results.

Application :

• Glassware (ampoules, vials, bottles)
• Containers and metallic components.
• Machine and change parts.
• Tanks and vessels.
• Hygroscopic pharmaceutical products.

To guard our complete range of goods from exterior causes that can be damaging, we have a high-tech packing unit armed with the newest safe packaging technologies and supplies. Our up-to-date logistic facilities support us in meeting the delivery deadlines promised to the customers.

 

Top Features :

• Vertical Top opening with soft hydraulic system to enable smooth operation of door
• Separate Jacket with heating system to enable fast heating of chamber
• All valves are electrically operated type hence pneumatic connection is avoided
• Semi automatic / fully automatic system with recording and printer
• Capacity range from 50 to 200 ltr
• All contact parts MOC in SS316L
• All connections are triclover end

SIP System Consits of:

• Pressure regulating valve.
• Steam trap.
• Pneumatic Diaphragm Valve to control Process.
• Temperature sensor.
• Pressure transmitter.
• Spare ports if required.

We have well-connected and capacious warehouse that helps us in arranging products systematically to deal with urgent deliveries and orders. Our exceptionally good warehouse system helps us in keeping the products safe till the final dispatch. Buyers can place bulk or retail orders with us all year round and expect on time delivery of consignments.

With the advent of steam sterilizer, we have succeeded in developing a bung processor system which can be washed, siliconized and sterilized and dried in one go without contaminating the bungs. This bungs can be directly used for further manufacturing activities in a sterile facility.
Processing of bungs is of high concern since they play a significant role in the quality and life of the final product.
The need for correct processing technology is even more important considering the complexities in the compounding of the rubber used for the closures.
The system has its own CIP facility for keeping the machine ready for new batch. Advance carriage design and drum design enables a smooth and easy operation for user.

Exclusive Features :

• Rotating carriage: A perforated carriage with view glass and designed in such way that percolation and cleaning of bungs from all sides has given us the confidence to overcome faulty process. There is no need of any cassettes, theses bungs will freely move inside the carriage for proper cleaning.
• Sprinkling manifold : The system is designed to provide proper mixture of water, detergent etc. in contact with the bungs through sprinkling manifold arrangement. This enables uniform sprinkling over the entire bungs.
• Fluidization manifold : Once the process starts the particulates settles in the bottom and this needs to be taken out from the chamber. This is done by providing air nozzles at the bottom of the chamber. Air is passed at high pressure in the system to form heavy froth. This froth carries the particles and dirt’s to the top surface of the water inside the chamber. At the middle level of chamber there is a drain connection which allows dirt to go out. This causes effective cleaning of system.
• Sampling system in the drain : during the stage of final rinse with WFI, the integrity of system can be checked online by a Conductivity sensor which ensure Proper washing of the bung.
• Clean In Place system (CIP) : The BUNG PROCESSOR has inbuilt Clean In Place (CIP) system for washing the chamber and the rotating carriage to prevent the dirt or debris to be carried out from one cycle to another. This is very important before the start of the "Rinse with purified water" and "Sterilization" phases.
• Drive System :The mechanism of drive system has to ensure zero leakage from drive connections and ensure minimum friction between contact parts. Specially developed gears are used to ensures no particle generation during the process and allows the absence of any lubrication. A special non-lubricated mechanical seal is used for pressure and vacuum tight operation of the driving system.
• Dual Operation : The Bung Processor is designed for dual operation. It means if you are looking for only sterilization of media and garments, then we can choose the appropriate option apart from bung processing this has saved additional space and investment cost at customer end.

Process For Bung Washing Programs :

• The Process of bung processing are loading, washing with detergent, D.M. water & W.F.I. rinsing, siliconization , sterilization and drying.
• Washing - The loaded bungs are washed with detergent solution via a fully automatic detergent dozing system to remove the particulates, dirts, debris from the bungs.
• Rinsing -The washed bungs are rinsed with deionized water and WFI water and the quality of WFI water at outlet is checked automatically to ensure the proper washing of the bungs.
• Siliconization - After cleaning closures are siliconized using a silicone emulsion or oil. Siliconization of closures is necessary to prevent the release of plasticizers and other compound added during the process, to prevent any reaction between the closure and the medication stored or to ensure smooth operation of the machines used for bunging.
• Sterilization - In Sterilization the closures are sterilized with steam. A pre-vaccum process is employed to ensure effective removal of air and penetration of steam.
• Drying - After sterilization the closures are dried using a vaccum drying process. The drying efficiency is further improved by the continuous rotation of the closures.

We make sure that the products that we deliver will remain completely damage free as we make use of the quality packaging material and have skilled personnel for the packing of the products. You can choose to make payment through offline and online mediums as per your convenience. We are well versed with all and we ensure that the transaction is transparent.

 

Details :

• Capacity range - 5 Kg to 10000 Kg.
• Equipments Provided - Manufacturing Vessel.
• Agitator with scrapper assembly for manufacturing vessel.
• Top entry/Bottom entry/Inline Homogenizer for manufacturing vessel.
• Lobe Pump.
• Vacuum Pump.
• Water Phase Vessel.
• Bottom/top entry mechanical stirrer for water phase vessel.
• Wax Phase Vessel.
• Bottom/top entry mechanical stirrer for wax phase vessel
• Interconnecting Pipelines.
• Manual/Pneumatic Butterfly valves.
• Conical Filter.
• Manual/ Electro-Pneumatic control panel.

In order to recover the clean condensed water and enable its reuse from the RO rejects and ETP solution we offer Multi effect evaporators. The system is used to reduce the water loss through double or triple Effect Combination Evaporator with one falling film type and one forced circulation type evaporators. The material of construction for all liquid contact parts in SS304 and Calandria tubes of SS304. All vapor and condensate contact parts will be in M.S.

Complete system will be under pressure at 3 kg/cm2( g).and consists of following components :

• Feed Pump : A centrifugal direct driven pump is used for transferring the feed solution from the balance tank to the Calandria. The pump is provided with a single mechanical seal and electrical motor. All contact parts with liquid will be in S.S.304.
• Calandria  : This Calandria is essentially a vertical shell and tube type vertical heat exchanger and is designed as per the Falling film /forced circulation principle. Steam is provided on the shell side and feed solutions is passed through tubes. The tubes of Calandria are of 25.4/ 31.75 mm OD. Adequate no. of tubes 4/6 M length are provided for the heat transfer duty.  The tubes are welded on the tube sheet.  The shell has nozzles for steam/vapor inlet and outlet, and temperature gauge. All Contact parts with liquid will be in S.S.304. Tubes will be of S.S.304. Thermic fluid/Steam and other non-contact parts will be in M.S.
• Vapor Separator : In vapor separator, the heated liquid coming from the Calandria is flashed. Saturated vapors coming out from top are sent to the next Calandria/condenser. Liquid concentrate coming out from bottom is withdrawn as feed to next Calandria/ as product. The separator shell has sight and light glass for viewing the concentrate level. Material of construction for all contact parts with liquid and vapor will be S.S.304 and non-contact parts will be in M.S.
• Re-circulation Pump : This pump is provided for re-circulation of slurry inside the heat exchanger, so as to increase the velocity of liquid inside the tubes and to get the required heat transfer. This is a Centrifugal Pump with double mechanical seal and motor. Contact parts will be in S.S.304. Concentrate outlet will be taken out from recirculation pump so the discharge head will be at around 5-6 meter only.

Condenser is used to condense the evaporation rate at the outlet of system. It also consist of condensate pot, condensate pump and vacuum pump.

Multi Column Distillation Plant is based on FINN-AQUA design. It consist of specially designed columns which make optimum use of the principles of inter stage heat exchange (Multi effect distillation method) to produce pure pyrogen free sterile distilled water for injectable as per IP/BP specification. The vapor with high velocity and under pressure passes over a SPECIALLY DESIGNED SPIRAL BAFFLE system which develops tremendous centrifugal force and thus eliminates any chances of pyrogens carry over in the vapors.
To industries where 100% pure Pyrogen - free water-for injection plays role, Multicolumn Distillation Plant is the perfect solution. Available in capacities ranging, the Multicolumn Distilled plant is used for its economy, low maintenance and low operation costs. By Multi Effect Distillation method significant energy (75% approx.) is saved when compared to the conventional method. All contact parts are made out of AISI 316 quality stainless steel and mirror polished. All pipes and tubes are essentially seamless.

Operation : The pre-heated feed water (through condenser) is fed into the first column where 33% of feed water is converted into steam under pressure by outside boiler steam. The pure steam produced in the first column having temperature of 135 degree Celsius and the remaining feed water goes to the 2nd column. The pure steam is used as a heating media in the 2nd column and converts part of remaining feed water into steam. In the process the steam itself condenses back into water. This process is repeated till the last columns each working at low temperature & pressure as compared to the one before it. The steam produced in the last column is condensed in the condenser by feed water as well as cooling water. As external heat is required only to convert the 33% of feed water, the heating energy required is reduced by 67%.

Construction Details :

• Distillation column houses the heat exchanger & pyrogen separation system.
• Heat exchanger in first column with Double Tube Sheet Design as per USP requirement.
• Common condenser at the end of distillation process to condense steam & separate gas from distillate
• Vent on the condenser is with 0.2 micron bacteria retentive filter for safe shut down.
• All seamless pipe with orbital welding inspected by boroscopic procedure.
• Designing is as per ASME std. All surface finish better than 0.3 Ra.

Salient Feature :

• Total energy saving is 75% as less heating energy and less cooling water is required.
• Pyrogens are removed by centrifugal force developed & specially designed spiral baffle.
• All contact parts are s.s.316 quality. All pipes and tubes are seamless and gaskets made form teflon.
• Distillate Temperature is quite high.( 90-95')
• Distilled water as per IP/BP standards and conductivity less than 1 micron/cm.
• Online temp. monitoring of WFI
• Conductivity monitoring and control for feed water & WFI
• Automatic feed water control to prevent column flooding.

The Bung Processor has inbuilt Clean In Place (CIP) system for washing the chamber and the rotating carriage to prevent the dirt or debris to be carried out from one cycle to another. This is very important before the start of the "Rinse with purified water" and "Sterilization" phases.

 

CIP System Consists of :

• CIP Tank 50 Ltr to 5000 Ltr.
• CIP Skid with mobile trolley.
• Acid Carboy.
• Alkali Carboy.
• Acid Dosing Pump.
• Alkali Dosing Pump.
• Supply pump.
• Recirculation pump.
• Heat Exchanger if required.
• Air Vent Filter.
• Level Sensor.
• Pneumatic Diaphragm valves to control process.
• Steam trap.
• Temperature Sensor.
• pH sensor.
• Conductivity sensor.
• Control panel with PLC/HMI & Printer.

We are capable of catering to buyers anywhere in Thane(India) as well as any other place. We have resources to reach the buyers' Thane(India) with ease. Our company has a convenient and noncomplex payment procedure. Patrons can make payments through a method with they are comfortable. We are open to receiving payment online or offline.

 

Details :

• With confidence of highly experienced team, we have developed a series of autoclaves with 3rd generation technology including latest 21 CFR part 11 compliance system and self-steam creator and water recirculation technology.
• Gemerik has also been successful in achieving the temperature accuracy level upto 0.2 deg C probe to probe under sterilization condition with automatic control of steam input. Today Gemerik has its own segment of simplest, cheapest, and most flexible autoclave which makes us extra-ordinary solution providers.
• This High Vacuum Steam Sterilizer is used for sterilization of machine parts, change parts, fabric, tubing, bulk drugs, etc. in a pharmaceutical facility.
• Capacity range from 100 ltr to 8000 ltr.
• All contact parts in SS316L
• All connections are having Triclover end.
• Inbuilt vacuum system.
• All cycles run through PLC / HMI programs hence totally automatic and accurate.
• We provide complete documentation of system.

Customized option for steam sterilizer :

• Single door or double door
• Shelve mounted or carriage and trolley arrangement
• Inbuilt control panel or separate control panel
• Inbuilt steam generator or per steam operated

In order to keep our offerings in safe and secure conditions, we have developed a storage unit and keep it updated with the defined industry standards. We are a quality-centralized firm and make use of only high quality material for manufacturing the offered lot. Also, we ensure that the material is sourced from the reliable places.

 

Details :

• We offer Super-Heated Water Spray Sterilizer for LVP / SVP / IV Bags / Glass Bottles / Plastic Bottles / Pouches.
• The design is based on uniform forced water circulation in a closed loop system through Heat exchanger.
• The key feature of this system is over pressure counter balancing inside containers during sterilization avoiding and cracking / breaking leakage / deformation of PP bottles due to internal pressure developed by the liquid product.
• The Heat Exchanger is shell and tube design used for heating and cooling the water during sterilization process.

The Process :

• Water is heated upto 121degC in a heat exchanger and circulated in the chamber. Water acts as a sterilizing medium in a closed loop system. 
• The compressed air is purged in the chamber to maintain the chamber pressure equal to the container pressure throughout the process. This support pressure is  totally  controlled automatically by the P.L.C.
• Thus heating – hold – cooling sequence is carried out with precision on both the vital parameters like temperature and pressure.
• The system follows counterbalancing of overpressure formed inside the containers during sterilization, avoiding breakages and deformation.

The most important equipment in any Pharmaceutical Plant manufacturing injectable solutions is the Pure Steam Generation Plant. Gemerik has developed WFI Still which produces distillate that meets the current U.S. and European Pharmacopeia for Water for injection guidelines equipped with a range of features to ensure that your installation and qualification is quick & trouble –free and that your WFI production remains efficient and reliable throughout your unit’s life.
Gemerik PSG is designed with efficiency keeping in mind. Because the system recovers the latent heat of vaporization which occurs within its own process to heat feed water and uses the feed water as the primary source of cooling.
Gemerik uses Corrugated Tube Heat Exchanger which is a next generation of Shell & Tube Heat Exchanger. With this technology we can achieve High Pressure & High Temperature with Less Maintenance & leakages. As heat exchanger has the main role in determining the efficiency of Pure steam Generator, we have achieved Higher Heat Transfer Co-efficient, Compact and economical model with reduced Fouling and dense turbulent flow even at low velocity.

Key Features :

• Capacity range 50 to 1000 kg/h.
• External evaporator, ease of maintenance.
• Unique optimized separation method.
• Full PID level control for safe consistent performance.
• In-house design and manufacture, cGMP double tube sheet heat exchanger, ensuring high quality control and consistency.
• cGMP design and regulatory compliance.
• Degasser option to reduce non-condensable gases.
• Research is undergoing with use of Corrugated Tube Heat Exchanger which is a next generation of Shell & Tube Heat Exchanger.
• With this technology we can achieve High Pressure, High Temperature, Less Maintenance & leakages.
• As heat exchanger has the main role in determining the efficiency of PSG and WFI, we have achieved Higher Heat Transfer Co-efficient, Compact and economical, model with reduced Fouling and dense turbulent flow even at low velocity.

Features :

• Vessel is a Vertical cylindrical with flanged end main shell & flanged end top dish along with tori spherical bottom dish welded to main shell.
• Vessel has 45 mm puff insulation cladding to avoid Heating-cooling transfer losses.
• Manhole / hand holes are provided depending on vessel size for viewing and maintenance of vessel.
• Sight glass with lamp is view the process inside the vessel in closed conditions.
• Vessel is provided with castor wheels or mobile skid to enable easy movement.
• Vessel is jacketed with steam / cooling water inlet / outlet facility to maintain the product temperature inside the vessel.
• For weight indication of product Load cell is provided.
• Various sensors are provided for process control like temperature sensors, level sensor, PH sensor, Conductivity sensor.
• Vessel is connected to CIP & SIP system for cleaning & sterilization purpose. To fulfill CIP & SIP purpose we provide a spray ball along with Manual Operated diaphragm valve.
• Control panel & vessel are provided on same skid.
• Design code is confirmed to ASME SEC VIII, DIV-I, Non IBR Pressure Vessels & BPE STD 2008.
• Vessel capacity Range from 3 ltr to 10000ltr
• Vessel Material of contact parts is SS316L and other parts are of SS304.
• Vessel are internally electro polished.
• All accessories like Load cell, Vent filter, spray ball, light glass, hand hole, ZDL valve, diaphragm valves, magnetic stirrer etc. are purchased from reputed makes.

We have well-connected and capacious warehouse that helps us in arranging products systematically to deal with urgent deliveries and orders. Our exceptionally good warehouse system helps us in keeping the products safe till the final dispatch. Buyers can place bulk or retail orders with us all year round and expect on time delivery of consignments.

 

Storage Tanks :

• WFI Storage tanks ranging from 1000 L – 25KL.
• PW/ RO/DM Water Storage Tanks (1000 L – 25KL)
• PW/WFI Skid with piping, looping & Distribution.
• Sterile & Aseptic Process Pipe Line Site activity.

Timely delivery of the orders is assured with us as we are backed by one of the most sophisticated transportation facility. Stay rest assured for the products that we offer as they will remain damage free. For this, we make use of only premium packaging material for the packing of the products.

 

Details :

• DHS uses dry air, hot air as  a sterilisation / de- pyrogneation medium at a  temperature of upto 250 dge C.
• Capacity Range From 160 to 2000 ltrs volume

Salient Features :

• Complies with requirements of HTM2010 and US FDA.
• Stainless steel construction with hydgenic design.
• Class 100opertation for maximum sterile integrity of the product.
• User friendly, automatic operation with on-line process doucmentation.
• In-built  ports for validation and perfomance qualification.
• Comprehensive safety features for  best results.

Application :

• Glassware (ampoules, vials, bottles)
• Containers and metallic components.
• Machine and change parts.
• Tanks and vessels.
• Hygroscopic pharmaceutical products.

To guard our complete range of goods from exterior causes that can be damaging, we have a high-tech packing unit armed with the newest safe packaging technologies and supplies. Our up-to-date logistic facilities support us in meeting the delivery deadlines promised to the customers.

 

Top Features :

• Vertical Top opening with soft hydraulic system to enable smooth operation of door
• Separate Jacket with heating system to enable fast heating of chamber
• All valves are electrically operated type hence pneumatic connection is avoided
• Semi automatic / fully automatic system with recording and printer
• Capacity range from 50 to 200 ltr
• All contact parts MOC in SS316L
• All connections are triclover end

SIP System Consits of:

• Pressure regulating valve.
• Steam trap.
• Pneumatic Diaphragm Valve to control Process.
• Temperature sensor.
• Pressure transmitter.
• Spare ports if required.

We have well-connected and capacious warehouse that helps us in arranging products systematically to deal with urgent deliveries and orders. Our exceptionally good warehouse system helps us in keeping the products safe till the final dispatch. Buyers can place bulk or retail orders with us all year round and expect on time delivery of consignments.