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System Integration

Much of our product range can be used alongside other equipment and, therefore, has been built with system integration in mind.

Integrated pharmaceutical powder processing

Hanningfield designs and supplies powder processing systems that connect milling, sifting, vacuum transfer and IBC blending. We consider the equipment interfaces during the design phase, whether your project adds a machine to an existing line or brings several process steps together.

Drawing on over 35 years of engineering and manufacturing experience, we combine custom-built machinery and procured items to deliver complete systems. A coordinated approach helps you address connections, product flow, controls, cleaning access and container handling alongside the main equipment.

From powder transfer to IBC blending

A typical arrangement can combine vacuum conveying with inline cone milling or sifting, feeding an IBC for subsequent bin blending. Weighing can be considered where required. The final arrangement depends on your powder, batch sequence, room layout and process requirements.

Discuss your system requirements

Share your process flow, powder characteristics, batch sizes, target throughput and existing equipment details. Include transfer distances, room heights, utilities, cleaning methods, containment objectives and the documentation you need.

Agree the scope of supply, responsibilities at each equipment interface and acceptance criteria at the start of the project. Contact your regional Hanningfield team to discuss a new system or an upgrade.

Please find below some example system ideas showing how processes can be integrated together for greater efficiencies >>

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Milling and Sizing:
Conical Mills (Under-Driven)
Conical Mills (Over-Driven)

Sifters (Centrifugal Screening)
Pre-Breakers
Particle Sizing Solution
Lump Breakers

Conveying and Transfer:
Vacuum Conveyors
Capsule Conveyors
Sack Tip Station
Powder Flow Control System

Lifting and Handling:
Hoists (Lift Systems)
Bin Blenders
Drum Tumblers
Drum Tippers
IBCs
Tablet IBCs
Stainless Steel Drums
R&D Blenders

Containment and Control:
Cyclones
Hygienic Valves
Silicone Dust Caps
Silicone Connector Sleeves

Unloading a Fluid Bed Dryer
Vacuum transfer can be used to convey material from an FBD after the drying process is complete (shown here with an in-line mill for improved PSD).
Dust Collection from a Tablet Press
Cyclone is designed to be connected to the extraction line of a tablet press, intercepting waste powder post-compression.
Powder Flow Control System
The system uses rotary valves, level probes and breather socks to control flow of powder between floors. This prevents over-filling of the lower-level machine.
Vacuum Transfer from Drum to Process Machine
The conveyor sucks material from a ground floor drum, up into the Uni-Vac hopper. Once full, the outlet valve opens and discharges the material into the machine.
Isolator Milling
The Uni-Mill is suitable for isolator integration using our 'through-the-wall' design. This mounts the milling head inside the isolator, with motor and controls external.
Lifting IBC above Tablet Press
The Uni-Hoist HES can be used to raise and dock IBCs above a process machine for discharging powder directly into the loading hopper.
Vacuum Transfer into a Vessel
Vacuum conveying can be used to transfer material from a ground-floor drum into a vessel or tank.
Raise and Lower of Mixer
The Uni-Hoist can be used for the simple raise and lower of mixers into vessels.
Loading Empty Capsules into Encapsulation Machine
The CapsuJet C20 loads empty capsules up into the capsule filling machine from the hopper at ground level.
Direct Loading (into Blender)
Where the receiving vessel is vacuum rated, material can be directly loaded by pulling a vacuum on the blender, with a filter hopper before the pump.
IBC to IBC Milling
By positioning a bin above the mill, and another bin below the mill, product is released from the top IBC, milled, and then passes directly into the bottom IBC.
Wet Milling (Post-Granulation)
Milling after granulation increases the surface area of the material. This enables a faster, more consistent drying process downstream.
Dust Collection from Capsule Filling Machine
The cyclone can alternatively be connected to the extraction line of a capsule filling machine, intercepting waste powder before it reaches the central extraction system.
Vacuum Transfer into a High Shear Mixer
Vacuum conveyors can be used as a dust-tight method to transfer powder from ground floor level into a high shear mixer.
Duplex Hoist for Fast IBC Changeover
The Uni-Hoist (HES Duplex) uses two independent lifting platforms; this minimises downtime as the empty bin can be replaced while the full bin is discharging.
In-Line Vacuum Milling
In-line vacuum transfer through a conical mill for achieving automated, dust-tight milling (same process can be achieved with an under-driven conical mill).
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Milling into Drum
The conical mill can be hand-fed allowing immediate discharge into the drum below (various methods of dust containment are available).
Sack-Tip Station Feeding Vacuum Conveyor
The bag is emptied into the Sack Tip Station, where the powder is then sucked away by the vacuum conveyor to a downstream process.
Table Top Laboratory Scale Milling
The Uni-Mill M05-U is suitable for table-top use, such as R&D or lab scale applications. Product can be milled into bags, drums etc (containment available).
Transferring Capsules After Filling
The CapsuJet FCC can be used to transfer filled capsules from an encapsulation machine to a downstream container or other process machine.
Drum Tipper Docking onto Isolator
The Drum Tipper provides repeatable and accurate docking of drums onto the inflatable seal port of the isolator.
‘Blend-in-the-Bin’ Blenders
Maximise productivity with ‘Blend-in-the-Bin’ (as opposed to conventional double cone or V-Blender), enabling immediate batch switchover without washdown.
Integrated Pack-Off System
In-line processes, such as sieving and milling, can be integrated with pack-off systems, including dosing valve, metal detection, continuous liner and weigh scales.
Delumper before Milling
A LumpBreaker can be used to pre-break agglomerated material (e.g. metformin) to aid downstream milling.
Docking Alignment between Mill and Upstream / Downstream
The Uni-Connect silicone sleeve compensates for the docking alignment between two pieces of machinery (e.g. outlet feeding conical mill inlet as pictured).
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