Return to sender

Ian Crawford, exhibition director of Total Processing & Packaging 2007 says the future of liquid handling involves hygienic and convenient returnable bag-in-box containers

In the pharmaceutical and cosmetics industries, it is essential that the risk of cross-contamination is kept to a minimum. Wearing protective clothing and washing hands in between handling different products will reduce the risk of transferring bacteria from one area to another. Packaging is also a good way to avoid cross-contamination. It acts as a physical barrier to bacteria, which is why nearly all cosmetics and pharmaceutical products are sold in some sort of packaging.

It is logical that the same concept applies to plastic returnable packaging, for example intermediate bulk containers (IBCs) and bag-in-box products. These are typically used for storing and transporting large amounts of liquids such as lotions, oils, creams and medicines. Returnable containers can be purchased or hired out for such purposes. In the case of hire, the boxes are likely to be used in more than one industry, which can encourage the risk of bacteria being transferred from the box to the product inside. It is vital that these containers are thoroughly cleaned before re-use to prevent the spread of germs and toxins.

IBCs have largely replaced traditional drums and canisters and are popular for both storage and transportation. They are large and robust and make effective use of the available space. The plastic container is protected by a wire cage that provides additional strength and rigidity. However, IBCs can be difficult and expensive to clean. Numerous labels may have to be removed from the exterior of the container, filters can become clogged and valves and other hardware must be disassembled to clean and then reassembled ready for re-use.

Typically, a container will be rinsed using water or gas, washed with a detergent, drained of all dirty liquid and dried. This method may give the appearance that the container has been cleaned but is unlikely to remove all the bacteria that may be lurking on or inside the container.

Hygiene & convenience

This is where bag-in-box returnable containers are more hygienic and convenient. A disposable liner bag is placed inside the box and filled with liquid. The bag is replaced every time the box is reused, which reduces the risk of transferring bacteria as the box never comes into direct contact with the product inside. It also saves time and money on physically cleaning the box and means that the box does not have to leave the factory to be cleaned before being used for another purpose.

Bag-in-box containers can be made from steel or plastic. Plastic is the most hygienic material for bag-in-box containers used to store pharmaceutical and cosmetic products. Unlike most cases with steel, plastic has rounded corners, which reduce the accumulation of dirt.

To find a more efficient plastic handling solution, a €7m development project was undertaken. The aim was to create a system that would reduce costs per trip compared to conventional systems considerably. Every stage of the handling chain was analysed to find a simpler solution for filling, emptying, storage, transport and cleaning. The result was the Combo, a new handling system for liquids that fulfils requirements on safety, hygiene and the environment.

The liner bag can be sterile or non-sterile and is filled without allowing air to mix with the product in the container. It can also be emptied without letting air into the box, which means the product is protected against external damage and oxidation. The packaging system dramatically reduces packaging costs compared to traditional alternatives but also simplifies handling throughout the logistics process providing safe and hygienic storage and transportation of liquids.

The Combo is manufactured in a dedicated production plant using the latest plastic moulding techniques, and is made from 100% polypropylene. This gives it exceptional strength and durability. It is returnable, reusable and, at the end of its working life, totally recyclable. The liner is also made from recyclable material, which reduces the use of packaging material. Lifecycle analyses conducted at the University of Lund in Sweden showed that the Combo dramatically reduces negative environmental impact compared to the most common systems used for liquid handling. It also offers quick payback on investment due to a significant decrease in material consumption.

With a capacity of up to 1000 litres, the Combo can be used to store and transport liquids and pastes for the cosmetics industry and it can also store powder and granules, making the product extremely versatile.

The strong welded construction means the product can be used in all kinds of transportation networks - road rail and sea - due to its ability to absorb the movement of liquid. The lid is locked to the sides with strong locking handles, which can also be sealed. It can also be ordered with a variety of accessories, including tamper evident seals and a level indicator, which tells the user when the content is getting low.

In addition to the removable liner bag, the box can be given a thorough wash down in a high hygiene clean room. A new cleaning system from JohnsonDiversey, consisting of a disinfectant and a dispenser, has been developed specifically for this purpose. The disinfectant is industry recognised and is effective against bacteria, yeast and fungi, killing organisms within five minutes of contact.

www.totalexhibition.com