A paradigm shift in pharmaceutical production: the benefits of continuous manufacturing

Big bag emptying to safe raw material transport — definition: Efficient raw material supply, from big bag emptying to safe bulk transport, covers validated process steps: FIBC discharge (OEB 1–5, ATEX zone 21), closed transfer via an SBK endless liner or split butterfly valve, and pneumatic or mechanical transport (ProClean Conveyor PCC) to the production area in line with GMP Annex 1 (2022), SMEPAC and OIML R 76 weighing.

Key points: big bag emptying to raw material transport

• Systems: LAS-EC big bag discharge station (FIBC type C/D), SBK endless liner connection, dense-phase conveying at 0.5–3 bar, OIML load cells ±0.1%
• Standards: ATEX 2014/34/EU zone 21, GMP Annex 1 (2022), SMEPAC OEB 1–5, OIML R 76, EN 13155 (lifting accessories), ISO 11228 (ergonomics)
• HECHT systems: LAS-EC big bag discharge station, LBK-EC endless liner, ProClean Conveyor PCC, pneumatic conveying system, HECHT IQ/OQ
• Applications: pharma (API/HPAPI big bags), food (flour, sugar, starch FIBC, EHEDG), chemicals (CMR substances, ATEX), battery production
• Result: a fully closed line eliminates dust exposure (<0.1 µg/m3 at OEB 5) and saves 1–3% of product compared with manual transfer

From big bag to production line — HECHT supplies the complete solution. See our big bag discharge stations and conveying systems, test your raw material at the Test & Trial Centre in Pörnbach or read about pharmaceutical raw material logistics.

In the first and second process steps, the focus is on safe, dust-free and GMP-compliant transfer of the raw materials – a central part of any continuous pharmaceutical production. The raw materials, delivered in big bags, pass through a carefully designed installation that offers maximum safety and availability in a tight space. A special feature of the project was the innovative gantry design, which greatly reduced installation complexity.

Essential components of the big bag emptying stations:

• Connection system for dust-free transfer to the suction shoe
• Support table to take the load
• Walking paddle to help discharge poorly flowing products
• Sturdy frame with pneumatic tensioning device
• Runway beam with chain hoist and lifting gear

Project highlights:

• Fivefold cantilever gantry with 3 gantry units and two cross-connections – enables space-saving installation
• AAS-EF system with two-handed lever technique and integrated dedusting filter
• Inline sieving machine for protective screening
• Mobile transport trolley for cleaning in a separate wash room

Conveying system with HECHT ProClean Conveyor (PCC):

• Flow-optimised pipework system
• Slightly conical separator vessel for better discharge
• ViwateQ surface finish against product build-up
• Discharge valve with pneumatic vibrator to prevent bridging
• Integrated weighing system for continuous, accurate dosing

FAQ — Big bag emptying to safe raw material transport

How do you reduce dust exposure when emptying big bags of hazardous powders?

For OEB 1–3: bag dump station with HEPA H14 extraction (0.5 m/s capture velocity at the working opening) plus an FFP3 half mask. For OEB 4–5 (HPAPI, OEL <1 µg/m3): LAS-EC big bag discharge station with SBK endless liner connection, closed transfer without a manual step. A SMEPAC measurement protocol verifies containment performance <0.1 µg/m3. HECHT carries out SMEPAC tests at the Test & Trial Centre in Pörnbach for FAT approval.

Which conveying method suits pharmaceutical raw materials best after big bag emptying?

Dense-phase pneumatic conveying (0.5–3 bar, low velocity 2–6 m/s) is the standard for pharmaceutical APIs: minimal particle breakage, no segregation, ATEX-compliant and CIP-cleanable. Compared with lean-phase: 80% less wear, 60% less particle breakage and a dust-free closed system. For abrasive powders (crystalline APIs, silica): HECHT ProClean Conveyor PCC with wear-resistant PTFE lining. Choose based on Carr index and particle size.

How do you ensure FIFO raw material management when discharging big bags in a GMP environment?

FIFO is ensured by: (1) barcode/RFID scan when placing the big bag on the discharge station (GS1-128, link to WMS/ERP via OPC-UA), (2) automatic batch blocking when the retest date has expired (21 CFR Part 11 electronic signature), (3) weight recording per discharge (OIML R 76, ALCOA+ digital record), (4) residual-weight alarm at <5 kg left in the big bag (prevents air blow-in). HECHT handles the MES integration and GAMP 5 validation.

Author: Joost van Velzen, Managing Director Hecht Technology B.V. Reviewed: 1 June 2026.

Keywords: big bag emptying safe transport pharma GMP SMEPAC, LAS-EC big bag discharge station OEB 5 ATEX endless liner, dense-phase conveying pharmaceutical raw materials containment, FIFO raw material management big bag discharge WMS OPC-UA, raw material supply big bag to production line HECHT

Continuous production does not end with transporting the raw materials – on the contrary: the final step, accurate dosing into the mixer, is crucial for the homogeneity and effectiveness of the end product.
In the customer project, five high-precision loss-in-weight feeders take on this demanding task.
They ensure that exactly defined quantities of the powdered raw materials are fed evenly and synchronously into the continuous mixer.

This way of dosing not only guarantees consistently high product quality, it also supports process stability and traceability – two central requirements of the pharmaceutical industry. By combining weighing and dosing technology with continuous feedback, the process is not only controllable but can also be actively steered.

Key elements of the final process step:

• Five loss-in-weight feeders
• Accurate, continuous dosing at high throughput
• Seamless integration into the continuous mixing technology
• Optimised process control through supporting weighing technology
• Basis for consistently high product quality and process safety