Batch Vacuum Process Plants

Type zoatec® BG
For flexible and efficient
production of pharmaceuticals
and cosmetics
BATCH SYSTEMS

For mixing,

dispersion and

homogenising

of liquid and

semi-solid products

For liquid processes

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 Your requirements –
Our solutions

• Flexibly usable plant

• Optimal space utilisation

• Easy compliance with GMP

relevant guidelines

• Reliable batch times:

Calculation using optimised
scale-up method

• Consistent product quality

with every batch

• Easy cleaning and

maintenance

• Low operating cost

• Simple operation

Perfect reproducibility and the highest hygiene standards

for liquid and semi-solid pharmaceuticals and cosmetics

We optimise your processes in our technical centre

Mixing, dispersion and homogenising are our passion
In our lab, we determine the process parameters that enable The modular assemblies of the zoatec® BG vacuum process plants are
reproducible attainment of the best product quality with the highest used in all situations where dry and liquid ingredients or combinations
hygiene standards. of liquid ingredients need to be combined for mixing, dispersion or
emulsification.
Thanks to our many years of experience in producing pharmaceutical .
creams, gels, lotions, suppositories and salves as well as top-quality
cosmetics, we can help you find optimal solutions to your requirements.

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The well-conceived design of the AXO LIQUIDS process plants
sets them apart from all conventional systems
We assemble complete process plants from standardised modules. We are experts at scaling up from the lab to the production environment.
These modules are independent of the process parameters and can Our plants are always optimally matched to your processes, your recipes,
be adapted to your needs very flexibly. your premises and your operating sequences – because we listen to you.

The individual modules can be installed in the equipment room or in This applies to the components, the CIP and SIP processes, the control
the production room – according to your wishes. software, qualification and validation, as well as the maintenance
procedures.

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 Optimal cleanout is especially Spray nozzles for residue-free
important for cost-effective CIP cleaning without manual
production of small quantities intervention

Homogeniser:
Easy access and low wear Blender combinations:
by design Optimal adaptation to
product requirements

Patented pump mode:

Non-destructive mixing of
chunky substances and f Insulated double jacket:
ast product discharge Fast heating and cooling

Our innovative design:

Modular is better

Honeycomb Separation of process

machine frames and supply modules

• Separate installation of process • Consistent frame shape • Separation of production and Avoids interference from the
and supply modules for easy upscaling) technical areas supply module when load cells are
used on the process module
• All components on the process • Frame accepts every container • Also enables installation in
vessel are easily accessible for shape without modification: constrained spaces
process handling, cleaning and Conical 80°
maintenance) Conical 130° • Easy implementation of
Dished, etc. extensions and specific
• Mounted on just four machine regulations (ATEX, sterile,
feet (four load cells with high hygiene, etc.)
readout accuracy)

Honeycomb machine frames Process and supply modules can be installed independent of each other
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Versatile blender and mixer AZO LIQUIDS Homogeniser

• Combinations with a fixed • Improved heat exchange • Constant product feed to the • The homogeniser pumps away
baffle and up to two movable tools results in small droplet from the shaft seal, resulting in
baffles are possible • More turbulence for size with optimal distribution less wear and longer seal life
shorter CIP process
• Other blending modules • High pumping and shear speed • The tool and shaft seal can
can be integrated (dissolver, • Shorter batch times for fast intake of large quantities easily be removed from the
rotor-and-stator homogeniser, of dry ingredients and reactive front for inspection, without
etc.) products major pipe dismantling effort

• Optimally adaptable to your • Fast product venting • High pump capacity enables
product requirements use as a CIP pump

A variety of blender combinations enable optimal adaptation to the product AZO LIQUIDS Homogeniser – The innovative core element of the process plant
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 Innovative homogeniser
with patented pump mode

AZO LIQUIDS Pump Mode

• Non-destructive blending of
sensitive products, for example
non-destructive blending of
care pearls without installing
an additional pump and piping

• Fast product discharge with

large batch sizes and shear-
sensitive products

• Better blending of large

quantities of dry ingredients Dispersion Mode Patented pump mode
m³/h (water)

Throughput in
dispersion mode

Throughput in
pump mode

Homogeniser throughput Homogeniser with flow direction away from the shaft seal
6 Comparison of throughput in dispersion and pump modes: Throughput is optimally matched
to the dwell time in the shear zone. (Nutritional value)
Type zoatec® BG Vacuum Process Plant
Best for batch! From quotation to automation

zoamatic Process Controller • zoamatic professional Dimensions

 odularly expandable concept
M
The zoamatic controller is an based on a SCADA system,
expandable system that covers extending to compliance with
the full spectrum of customer FDA regulations according to
requirements – from individual CFR21, Part 11. Project execution
basic control functions to fully according to GAMP and an
automatic recipe mode and even ISA S88.01 compliant software
complete batch documentation. structure can be implemented.
• zoamatic remote
Controller versions: F
 ull PLC controller with interface
• zoamatic smart for connection to an external
B
 asic HMI solution for a system
predefined functional scope • zoamatic lib
For integration into another system

Technical specifications of zoatec® BG Batch Vacuum Process Plant

Sizes: BG: 10, 100, 200, 400, 800, 1.200, 2.000, 3.000, 5.000 (larger capacities available upon request)

Size Minimum Maximum Process module Weight Supply module Weight

Start capacity Usable capacity A B C D E F
[litre] [litre] [mm] [mm] [mm] [kg] [mm] [mm] [mm] [kg]

BG10 4 10 800 900 1.500 350 600 600 1.600 150

BG100 40 100 1.200 1.200 1.850 600 900 800 1.600 200

BG200 80 200 1.400 1.400 2.350 750 1.050 800 1.800 250

BG400 150 400 1.600 1.600 2.600 1.000 1.050 800 1.800 350

BG800 340 800 2.000 2.000 3.000 1.500 1.250 1.000 2.000 – 2.200 500

BG1200 430 1.200 2.200 2.200 3.200 2.300 1.250 1.000 2.000 – 2.200 700

BG2000 760 2.000 2.400 2.400 3.600 3.000 1.500 1.000 2.200 – 2.500 900

BG3000 1.240 3.000 2.700 2.700 3.900 4.500 1.500 1.000 2.200 – 2.500 1.500

BG5000 1.890 5.000 3.200 3.200 4.300 11.000 1.500 1.000 2.200 – 2.500 3.500
Larger plants and dimensions for 130° conical and dished containers available upon request. Subject to technical changes without prior notice.
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 10230 2058 GB
Our spectrum of services:

••Engineering for entire plants and complete

AZO group projects
••Qualification and validation
••Custom plant engineering (continuous plants,
late stage mixing, etc.)
••Sterile versions and ATEX applications
••Customer Process Centre (CPC): Including trials
with customer products, product analyses, and
scale-up calculations
••Project management
••Consulting, process analysis and process optimisation
••Software systems conforming to CFR 21 Part 11
(new installations, updates and upgrades)
••Commissioning and training
••Conversion, maintenance and repair
••After Sales / Support & Service / Replacement Parts

AZO LIQUIDS GmbH

D-79395 Neuenburg am Rhein
Tel.: +49 7631 9739 0
[email protected]
www.azo.com