Bespoke plant solution for modern enzyme production
Die Partnerschaft zwischen der HECHT Technologie GmbH und einem weltweit führenden Biotechnologieunternehmen markiert einen bedeutenden Schritt in der Entwicklung zukunftsweisender Produktionslösungen für industrielle Enzyme. Das Biotechnologieunternehmen, spezialisiert auf großtechnische Fermentationen, produziert sowohl flüssige als auch pulverförmige Enzyme für den Einsatz in verschiedensten Branchen.
Um diesen anspruchsvollen Anforderungen gerecht zu werden, entwickelte HECHT eine speziell angepasste Sonderanlage, die auf die sichere und effiziente Verarbeitung sensibler Schüttgüter ausgelegt ist.
Im Zentrum der Anlage stehen mehrere Entleerstationen für Big Bags mit verschiedenen Anschlusssystemen – darunter Gloveboxen, das Containment-Anschlusssystem LAS-EC („EASY“) sowie SoliValve-Anschlusssysteme. Diese Komponenten ermöglichen ein ergonomisches, sicheres und kontaminationsfreies Entleeren der Enzyme und Trägerstoffe.
Die verwendeten Systeme sind exakt auf die spezifischen Anforderungen der Produktarten und deren Herkunft abgestimmt: Während SoliValve-Stationen für hauseigene Enzyme genutzt werden, kommen Gloveboxen und LAS-EC-Anschlüsse für externe Produkte zum Einsatz.
Damit wird ein hohes Maß an Flexibilität sowie Produktsicherheit gewährleistet.
Maximale procesveiligheid en efficiëntie dankzij intelligente installatiearchitectuur
The installation designed by HECHT impresses with a continuous process flow focused on precision, speed and safety. The pre-dosed enzymes are fed very accurately into the downstream dosing hoppers using SoliValve technology.
From there, the substances are conveyed onwards by HECHT vacuum conveyors of type PCC 300/300.
Enzymes and flour – the latter from silos – are combined in a central mixer. The flour is first conveyed through a line with a horizontal metal separator to reliably exclude any contamination from metallic foreign objects.
A special feature of the installation is the time-optimised dosing during the mixing and emptying phase, which reduces downtime and increases production capacity. After mixing, the product is emptied into a buffer container and fed to the filling line via a further PCC 700 conveyor.
Filling takes place after upstream sieving and inline sampling with HECHT screw samplers. A final metal detection with reject further increases product safety. Filling is carried out under containment conditions, either into big bags via the LBK-EC system or into small bags with automated valve setting.
The entire installation meets the requirements of containment category OEB4 (1–10 µg/m³), which ensures safe handling of sensitising enzymes and consistently protects employees.
Automation and efficiency were also a focus of the control system: internal processes are largely automated, so only two trained operators are needed.
The installation is controlled via the inventory management system – call-off orders are processed directly and raw materials are released by scanner, which avoids recipe errors. In addition, several buffer and storage containers allow virtually uninterrupted production.
The installation designed by HECHT impresses with a continuous process flow focused on precision, speed and safety. The pre-dosed enzymes are fed very accurately into the downstream dosing hoppers using SoliValve technology.
From there, the substances are conveyed onwards by HECHT vacuum conveyors of type PCC 300/300.
Enzymes and flour – the latter from silos – are combined in a central mixer. The flour is first conveyed through a line with a horizontal metal separator to reliably exclude any contamination from metallic foreign objects.
A special feature of the installation is the time-optimised dosing during the mixing and emptying phase, which reduces downtime and increases production capacity. After mixing, the product is emptied into a buffer container and fed to the filling line via a further PCC 700 conveyor.
Filling takes place after upstream sieving and inline sampling with HECHT screw samplers. A final metal detection with reject further increases product safety. Filling is carried out under containment conditions, either into big bags via the LBK-EC system or into small bags with automated valve setting.
The entire installation meets the requirements of containment category OEB4 (1–10 µg/m³), which ensures safe handling of sensitising enzymes and consistently protects employees.
Automation and efficiency were also a focus of the control system: internal processes are largely automated, so only two trained operators are needed.
The installation is controlled via the inventory management system – call-off orders are processed directly and raw materials are released by scanner, which avoids recipe errors. In addition, several buffer and storage containers allow virtually uninterrupted production.
Duurzame toekomsttechnologie met maximale prestaties
With an annual throughput of 17,000 tonnes, the new installation sets new standards in industrial enzyme production. It not only meets the highest requirements for efficiency, safety and quality, but also actively contributes to sustainability.
The installation is cleaned in two stages: dry cleaning with flour for the dosing and feed stations, and wet cleaning from the mixing process onwards. This combination ensures compliance with the strictest hygiene standards.
The integration of an energy-efficient management system and the use of resource-saving materials underline the focus on environmental friendliness. In addition, the intelligent plant concept allows flexible scaling – new product variants or changed production volumes can be realised without major modifications.
Thanks to its technologically advanced design, compliance with strict GMP and FDA regulations, spatial flexibility and an innovative filter concept in the PCC 700 conveyor, the installation offers a future-proof platform for biotechnological applications. It combines innovative strength, safety and environmental awareness at the highest level.
The result of this collaboration is a state-of-the-art, sustainable production facility that can serve as an example for industrial enzyme production – a milestone on the way to efficient, safe and responsible biotechnology of the future.