Access barrier avoids decontamination periods

A restricted access barrier system isolator optimises the aseptic packaging of milk and drinks and allows up to 72h of non-stop production without intermediate decontamination periods.

Serac of France, a manufacturer of filling and capping machines, has just launched a new RABS (Restricted Access Barrier System) isolator to optimise the aseptic packaging of milk and drinks in and around sterile areas.

Serac will be present at the Emballage trade show in Paris from 21 to 24 November 2006.

Serac's RABS isolator offers three major improvements over a standard isolator, in addition to established advantages - unidirectional flow, barrier zones and easy access.

It increases productivity in complete safety by enabling up to 72h of non-stop production without intermediate decontamination periods.

As opposed to a standard isolator, the RABS is not hermetically sealed: it is an air barrier produced by positive overpressure inside the enclosure that protects the sterile area.

Air is continuously circulated and renewed via a vertical unidirectional speed-regulated airflow.

Combining both these techniques eliminates the particles present in the enclosure and provides protection against external contamination.

By avoiding containment, the continuous air circulation extends aseptic state time and provides up to 72h of production without the need for intermediate decontamination.

The sterile area is surrounded by barrier zones that are also subjected to unidirectional airflow.

They act like an additional protective envelope between the enclosure and the rest of the workshop and make cleaning and maintenance operations on the machine easier.

The heart of the machine - the sterile enclosure - can only be accessed in production via glove boxes that are placed at critical locations along the filling line.

However, all the other points - treatment, line input and output - can be reached via external doors without users having to wear clean room clothing.

All access into and out of the barrier zone is monitored and recorded to effectively track operations.

The origins of this new type of RABS isolator stem from the pharmaceutical industry.

To design its isolator, Serac drew inspiration from the definition by the ISPE (International Society for Pharmaceutical Engineering) for the FDA (Food and Drug Administration).

This definition concerns seven criteria: solid partitions, providing a physical separation between production and the operators; unidirectional airflow (ISO 5); gloves or an automation system to avoid access when filling; an equipment transfer system to avoid exposure to less clean environments; high levels of surface disinfection; ISO 7 environment class; and, finally, rare interventions would require decontamination after intervention, doors to be locked and monitored, positive overpressure and ISO 5 environment class.

* About Serac - Serac SAS was established in 1969 and specialises in manufacturing filling and capping machines for liquid and semi-liquid products, along with complete packaging lines.

The company, which is headquartered in north-west France, is present in market segments covering food, industrial, chemical and hygiene products (perfumery, cosmetics and pharmaceuticals).

It has submitted around 80 patents in the packaging sector.

It employs 350 staff across three sites in France and eight subsidiaries or branches abroad.

Its turnover is over EUR 70 million, 85% of which comes from export sales (to approximately 80 countries).

Serac is used by world-leading groups such as Nestle, Candia, Lactalis, Coca-Cola, BP, Shell, Colgate, Danone, Unigate, Teisseire, Total, Procter and Gamble, Kodak and L'Oreal.

Serac has delivered six aseptic machines over the last two years, including two in Japan.

Serac will be present at the Emballage trade show in Paris from 21 to 24 November 2006.

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