Bung Processor

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.