Isolators, Robotics and Decontamination Systems

Shibuya Hoppmann Corporation has a variety of systems for the pharmaceutical industry that include decontamination systems, isolators and robotics.

Multi-Purpose Isolator with integrated HYDEC Decontamination Unit
Isolators
Dual Arm Robot Isolator (CellPro)
Robotic Systems:
Robotic Gift Packaging System
Box Opening Closing
Robotic Tank Washing System
Robotic System for the Alignment of Optical Filters

Multi-Purpose Isolator with integrated HYDEC Decontamination Unit

Applications for such equipment include: Sterility Testing, Small Scale Clinical Filling, Biohazard Products, Chemical Hazards, Hospital Preparation, Mixed Injection, and CPC - Research and Production. The HYDEC (Vaporized Hydrogen Peroxide Decontamination System) Model 2200 is a decontamination system developed by Shibuya using a more advanced concept than traditional vaporized hydrogen peroxide decontamination systems. The Model HYDEC 1000 series is capable of decontaminating volumes up to 1.5m3 and the Model HYDEC 2000 series is capable of decontaminating volumes greater than 1.5m3.

HYDEC Features

• HYDEC is an automated system to assist professionals in the control of potentially hazardous microorganisms.
• HYDEC requires no preconditioning.
• Continuous replenishment of H2O2 during the process is not necessary for the HYDEC.
• HYDEC uses less H2O2 and completes the decontamination cycle in less time than the competition.
• HYDEC is environmentally friendly since H2O2 breaks down into water and oxygen.
• HYDEC can be used as stand-alone or integrated into an Isolator.
• H2O2 is a powerful killing agent but yet is not aggressive to most building materials and/or electronics.
• Shibuya can provide the equipment, generate the cycle development as well as validate the system.

Multi-Purpose Isolator Features

• Built-in HYDEC with rapid cycle/aeration times.
• Low H2O2 injection volumes reducing risk of testing problems or materials compatibility issues.
• Uni-directional air flow.
• PLC control for both HYDEC and isolator from a simple user friendly touch panel.
• Can easily accommodate membrane filtration sterility test or direct inoculation testing.
• Pass box for entry of additional test articles or testing materials.
• Robust, high quality construction.
• Validation support and simple cycle development with full scientific support.
• Ergonomics can be adjusted for working in either a standing or sitting position.

(click on thumbnail to enlarge)

HYDEC Decontamination System

H2O2 Sterilization Unit

Back to top

Isolators

Shibuya manufactures a wide range of customized Isolator designs suitable for Production & Test filling lines, Hazardous testing, Clinical trial, Sterilization testing, Cell culture and many other applications. These isolators that achieve Class 100 aseptic environments. These systems have uni-directional or turbulent airflow and are custom designed for your individual needs. They can be fully integrated with VPHP decontamination systems and Shibuya provides full validation services (IQ/OQ/SQ, protocol and execution).

(click on thumbnail to enlarge)

Built in Isolator Unit

Custom Isolator for Vials

Dual Arm Robot Isolator (CellPro)

Shibuya Hoppmann's Robot Isolator termed CellPro, is a system designed to replace human operators in sterile-manufacturing processes that carry the risk of contaminating sensitive products or harming personnel. The system includes Shibuya's rigid wall isolator, Shibuya's decontamination system called the HYDEC and FANUC robots, which are specially designed to resist hydrogen peroxide. Shibuya and Fanuc collaborated on the robot design to allow for the robot to function in ISO 5 environments without contributing a significant amount of particulates under typical working conditions.

Design features such as internal air purge, special seals at all joints, hydrogen peroxide resistant covers, enclosed electrical cables and lack of retention areas help resist bacterial growth on the robots and reduce the potential for contamination all under aseptic conditions. CellPro can incorporate multiple robots inside the isolator depending on the application required. Shibuya has designed a unique control system for the robots within the isolator utilizing hand-held controllers similar to the Nintendo Wii. This patented solution allows the operator to control the robots remotely and even train precise tasks that the robot duplicates based on the operators movement.

With Shibuya's state-of-the-art decontamination system, termed HYDEC, integrated into the Robot Isolator, aseptic conditions can be achieved in shorter time periods and utilizing less hydrogen peroxide than conventional systems. With this advantage as well as utilizing robots, the CellPro can increase operator safety by compounding potent drugs, manufacturing radiopharmaceuticals or handling cytotoxic ingredients. CellPro also reduces contamination risk in aseptic environments by replacing humans in cell-culturing, sterility testing and aseptic-processing applications. The collaboration between Shibuya and FANUC is one example of the technological advances that can improve safety, quality and efficiency in packaging machinery.

Various applications for this system include:

(click on thumbnail to enlarge)

H2O2 Resistant Dual Arm Robot

Dual Arm Robot in Isolator

H202 Resistant Robot Flyer (PDF - 234KB)

Back to top

Robotic Systems

We combine the best matching robots for the purposes, so you can build up the optimum system. The following are a variety of different Robotic Systems provided by us.

Robotic casing system

Robotic placement system

Robotic Gift Packaging System

This robotic-packing system allows a wide variety of products to be assembled into a single package in small quantities. The system provides automatic pattern changes or the easy addition of patterns for packaging flexibility.

Box Opening Closing

This machine combines mechanisms of both the unscrambler for supplying resin containers to the line and the uncaser for supplying glass containers. By exchanging the robot gripper and moving the bucket conveyor, two different types of containers can be handled by one machine allowing for a compact line.

Robotic Tank Washing System

This system is designed to wash out the tank automatically. This robot washes the outside (top and side), the inside (with jet injection from discharge section) and the bottom (with the bottom unit).

Robotic System for the Alignment of Optical Filters

Optical filters are picked from a tray, inspected and the good filters are then placed in a second tray after precise orientation. The system contributes to improved productivity by minimizing inspection errors.

Back to top