Contributing towards improved safety in pharmaceuticals, through robotics technologies and 6D level decontamination powered by instantaneous light irradiation.
Announcing the "Pulsed Xenon Decontamination System for Nested Tub"
Nov 25, 2024
Iwasaki Electric has announced the development of its "Pulsed Xenon Decontamination System for Nested Tub", created to decontaminate Nested Tubs (※1) which are widely used in the medical field.
The "Pulsed Xenon Decontamination System for Nested Tub" combines 6D level (*2) xenon decontamination with robotics technologies, contributing towards improvements both in safety and productivity in the management of pharmaceuticals.
Pulsed xenon irradiation decontamination is delivered by utilizing xenon lamps with wavelengths that produce a decontaminating effect, to emit high-powered pulses (*3). With the light being emitted instantaneously, it is possible to achieve 6D level decontamination whilst minimizing the impact of ultraviolet and infrared rays on the target object.
The conventional procedure for filling pharmaceutical products into syringes sees nested tubs containing syringes removed from their sealed packaging, and transferred to a Grade A (sterile) filling area; this stage of the process presents the risk of contamination of the nested tubs.
Working to eliminate this risk, the solution presented by Iwasaki Electric sees pulsed xenon irradiation utilized to decontaminate the packaging during the transfer from opening site to sterile filling area, which is carried out by automated transport robots.
In implementing this system, factors including the decontamination level, installation environment, and cohesion with existing system are all taken into consideration, with a management process covering the project from design through to production in order to support the creation of a cleaner environment whilst also offering peace of mind.
- *1 Nested Tub: A container designed for transporting syringes (the outer tube of a syringe, with the needle and plunger removed).
- *2 6D: A measurement unit of capacity, applied to decontamination and sterilization. 6D represents the capacity to reduce pre-irradiation contaminants by six orders of magnitude (100% → 0.0001%).
- *3 Pulsed emission: Rapid flash lighting at extremely short intervals.
Operating Process Image
Key features of the pulsed xenon decontamination method
High-level decontamination effect
Pulsed xenon lamps deliver instantaneous and extremely high levels of light output vis-a-vis conventional UV decontamination, enabling decontamination up to 6D levels.
| Low pressure mercury vapor lamp (medium output type) | Low pressure mercury vapor lamp (high output type) | Pulsed xenon lamp | |
|---|---|---|---|
| Irradiation time | 16.5 seconds | 3.8 seconds | 1 pulse (0.5ms or less) |
| Decontamination capability | 3D | 3D | 6D |
Continuous irradiation with highly effective UV spectrum
As UV light in the 200-300 nm wavelength range - the most effective for decontamination purposes - is emitted continuously rather than as an emission line, greater decontamination benefits can be expected.
Minimized impact on the subject
Thanks to the extremely short lengths of irradiation time under the pulsed light emission method, there is virtually no deterioration or thermal effect on the target object resulting from the impact of ultraviolet or infrared rays.
Short processing time and in-line operation for improved productivity
The brevity of the processing time allows for incorporation into a filling line, enabling efficient handling at any scale from small lots through to mass production.
| Processing method | Processing time |
|---|---|
| High pressure steam | approx. 60mins. |
| Gas | 12 - 18hrs. |
| Formalin | 12 - 14hrs. |
| Pulsed xenon | 0.5 - 1sec. |
* Dependent upon the target object and conditions
Safe, with no residue and no need for after-treatment
Unlike gas or chemical based treatments, this method leaves no residues and does not require secondary treatment. Furthermore the use of mercury-free lamps prevents the generation of harmful ozone, making it a safe and environmentally friendly solution which contributes towards a reduction in environmental impact.
| Gases / Chemicals | Pulsed xenon lamps | |
|---|---|---|
| Safety and security | Residual and carcinogenic | Residue free |
| Regulation of secondary processing | Emission regulations in place | Unregulated |
At Iwasaki Electric we utilize the characteristics of light across a variety wavelength ranges, including not only visible light, but also ultraviolet, infrared, and electron beams, to deliver solutions to our customers in the healthcare industry.
In the event of improvements and developments, product specifications and appearances may be amended without prior notice.