Mastering a move-in

In the pharmaceutical industry, moving a GMP-compliant machine, such as a pharmaceutical washing machine or autoclave, isn’t just about getting it from point A to point B. It’s a detailed process that demands thorough planning, specialized knowledge, and precise execution. Freek and Dayo from eyetec are highly skilled in relocating and installing pharmaceutical machines with care. 

The move-in process involves several stages, each with its own set of challenges. From preparation and transport to installation and testing, every detail matters to ensure the machine integrates seamlessly into its new environment. 

Preparation and planning 

The first step in any successful move-in is preparation. Before the machine is even touched, it’s crucial to inspect the new location. Freek and Dayo begin by inspecting the new location, ensuring it meets the specific requirements for GMP equipment. This includes assessing the floor’s structural integrity and utility connections.  

Logistics are another key component. Planning the transport route, identifying obstacles, and coordinating the required tools and equipment - whether cranes, rollers, or forklifts - are essential to avoid complications. Careful consideration is also given to how the move might affect other operations, such as temporary utility shutdowns or the potential spread of particles in sensitive cleanroom environments. 

Our colleagues Freek and Dayo ensure that potential disruptions to other production processes are evaluated, such as the temporary shutdown of utilities or the impact of dust and particles on adjacent cleanrooms and HVAC systems. This comprehensive approach minimizes operational risks and maintains compliance across the facility. 

Transporting the GMP machine 

With the groundwork complete, the focus turns to relocating the machine. Freek and Dayo carefully select the appropriate method based on the machine’s size and weight: 

• Lifting equipment: Cranes, hoists, or forklifts are used for larger machines, with strict adherence to weight limits and safety protocols. 

• Wheels and rollers: Smaller machines are moved using rollers or wheels, ensuring a clear, obstacle-free path. 

• Removing old equipment: When replacing an old machine, safely dismantling and removing it is essential to ensure a smooth move-in. Freek and Dayo carefully remove the equipment and disconnect utilities, especially if they will be reused for the new machine. 

Throughout the transport, the machine is securely fastened to prevent damage. Regular checks ensure the move runs smoothly, addressing any issues immediately so the machine arrives intact and ready for installation. 

Installation 

Proper installation is critical to the performance and longevity of pharmaceutical equipment such as autoclaves or GMP-certified washing machines. Freek and Dayo focus on two key elements during this stage: 

Positioning and alignment 

Ensuring the machine is precisely positioned and aligned is essential. Even minor misalignments can impact performance, and reduce the machine’s lifespan. Freek and Dayo take meticulous care to align the machine according to manufacturer specifications. 

Configuring operational parameters 

Once the machine is in place, parameters like speed, temperature, and other settings are carefully adjusted. These configurations are aligned with the machine’s operational requirements. 

Additionally, the machine is securely anchored to prevent vibrations and utility connections are thoroughly checked to guarantee a seamless startup. 

Testing phase 

Before a machine is fully operational, it undergoes a rigorous testing phase to ensure functionality and safety. A tailored test protocol is created for each machine, reviewed, and approved by the client. 

Key testing steps 

1. Static tests: The machine is inspected for missing or improperly connected parts, especially utilities that may have been disassembled during transport. 

2. Dynamic tests: Once static checks are complete, the machine is powered on and tested under real-world conditions. 

3. Safety system checks: Emergency stops and safety switches are thoroughly tested to ensure proper operation. 

4. Functional testing: After successful safety and performance tests, the machine is evaluated for its intended operational functions. 

Addressing issues 

During testing, potential problems like vibrations from misalignment, electrical faults, or hydraulic/pneumatic leaks are identified and resolved. These steps ensure the machine is fully optimized and ready for use. 

Common Issues during the move-in process

Despite careful planning, certain problems can arise during a machine move-in: 

1. Incorrect installation or alignment: Misalignment can cause wear, reduced performance, and long-term damage. Precision alignment is crucial. 

2. Improper or incomplete connections: Incorrectly connected utilities such as electricity, air, or water can lead to malfunctions or even hazards like fire. 

3. Lack of training: Without proper training, staff may misuse the machine or fail to operate it efficiently, risking damage or downtime. 

4. Inadequate testing: Skipping or rushing test procedures can leave hidden issues unresolved, impacting the machine’s performance over time. 

Addressing these issues proactively ensures a smooth move-in and reliable operation. 

Conclusion 

The move-in process for pharmaceutical machines demands expertise at every step - from preparation to installation and testing. Freek and Dayo’s systematic approach ensures machines are relocated and installed with minimal risk, optimal performance, and compliance with industry standards.