Pharmaceutical Packaging Company Increases Safety and Efficiency with Iso-Roll Door

November 16, 2016

Challenge

PCI executives discover Cleanseal door solution while attending Pack Expo

“Trade shows are a convenient and efficient way for us to stay abreast of the latest technologies that will keep us competitive,” says Russ Stevens, PCI’s senior manager for facilities engineering and maintenance.

A global leader in pharmaceutical and healthcare packaging, PCI provides customized packaging services for several delivery forms including oral solids, powders, and parenterals at its 14 sites in North America and Europe. Providing packaging for global markets in excess of more than 100 countries, PCI supports clients in bringing more than 50 products to market each year. PCI’s network of clinical and commercial packaging sites are located in Philadelphia; Woodstock and Rockford, Ill.; and Wales.

As a contract packager, PCI works with clients from the earliest stages of clinical development through to commercialization and ongoing commercial supply. Ensuring an environment that implements current good manufacturing Practices (cGMPs), alongside appropriate design, supervision and control of manufacturing processes is critical to preventing particle contamination that can threaten the safety and integrity of pharmaceutical products.

As an example of how PCI integrates new systems and technologies into its operations, Stevens points to the search for improved sanitary doors for the clean rooms at its Rockford site — 1 million square feet over nine facilities. Because some rooms require a higher level of isolation and containment than others, PCI needed doors that would isolate air infiltration, minimize potential contamination and ensure compliance with safety requirements. The search ended at PACK EXPO 2010, where the company found Cleanseal Door Systems’ 415 Iso-Roll high-speed pharma door.

After a demonstration of the company’s doors, PCI executives were confident that they had found the right technology to meet their needs.

Solution

Iso-Roll's soft bottom edge flexes harmlessly if a worker bumps the door while passing trough

Compliant with cGMP, U.S. Food & Drug Administration (FDA) and European Medicines Agency (EMEA) safety standards, Cleanseal’s Iso-Roll Door provided the right barrier between PCI’s packaging
suites, enhancing efficiency and preventing cross-contamination and maintenance issues. And, with no special training or mechanical knowledge required to operate the doors, PCI had a seamless transition to the new technology and easy day-to-day traffic flow between the packaging suites.

Furthermore, the doors featured stainless steel components for easy cleaning, and a safe and soft bottom edge that flexes harmlessly if a worker bumps the door while passing through. Also in this instance, the doors’ break-away capabilities allow them to automatically reset to keep traffic flowing and increase productivity. The standard photoeye feature and motion sensor in the side frames automatically reverse when door comes down, allowing for the easy passage of workers carrying delicate materials.