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   2. Systems in pharmaceutical manufacture
Photo of reactor floor
Picture 2.3 This area of a factory was designed using 3D models on a computer.
Typical 3D model by Foster Wheeler.
IT systems
Pharmaceutical companies invest heavily in the latest technology. This allows them to develop new, high quality products quickly.

Both Pharmaceutical Research organisations and Engineering houses designing and building facilities use Knowledge Management Systems to store their technical know-how, allowing easy retrieval and global sharing of data.

Computer based 3D models are used in detailed designing of Pharmaceutical facilities to ensure that all building and process plant items fit first time. The virtual model allows operators and engineers to 'walk through the facility' to check the design works and meets the need of the operators. Behind the virtual plant an engineering database holds details of all the parts, which are used to create construction drawings and material orders for plant erection.

Research teams also use computers to generate new molecules. To combat a particular disease, these molecules have to have the right shape and chemical properties. Having generated some new molecules, the scientists can use computer models to screen them. During the screening, they pick out the ones that are likely to have the right properties.

Using the computers, they can generate and screen up to 10 000 new molecules a year. Without computers, it would take up to ten years to generate and screen this many molecules.

Photo of inhaler
Picture 2.4 A dry powder inhaler.
Delivery systems for medicines
Technologists have created many large-scale systems to help in the manufacturing process. You can see some of these in chapters 5 and 6. Less obvious than these is the work they have done on delivery systems. Again, problem-solving expertise is vital.

One example is the inhaler. The medicine is released in a fine spray or a powder and passes directly into a patient's lungs. This allows asthma sufferers to get fast relief from breathing difficulties

Control systems
Throughout the manufacturing process, there is a need for control systems. These may be automated or use human judgement. They are to check when part of the process is complete and that everything is being made correctly. For example, there are:
  • counters to ensure the correct number of tablets go in a container
  • cameras that 'check' if blister packs of capsules are full
  • electronic weighbridges to ensure that cartons are full of tubes of creams
  • devices that detect unwanted microscopic particles of metal in tablets
  • optical sensors to check that bottles have been filled to the proper levels
  • pH sensors to check acidity.
Photo of pneumatic system
Picture 2.5 An automated process.
Technological systems
There are many technological systems that make up the essential parts of manufacturing machinery. These use mechanical, electrical, microelectronic, hydraulic and pneumatic components to control and automate the processes.

Many of these systems appear in the case studies in chapter 5 and chapter 6.

Question 4

Look at the items below. In each case, decide which system it belongs to. Make your choice using the drop down menu.

Item which system?
a)  a pneumatic arm for picking up cartons
b) an emergency syringe for diabetics
c)  a program that matches the shapes of new molecules to natural molecules
d)  stamping the batch number onto a packet of tablets
e)  a gate that rejects cartons that weigh less than the weight of a full carton.