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<p>This paper presents a comprehensive optimisation and evaluation of an automated de-bagging process for aseptic manufacturing, where a double-bagged product must be transferred from a non-sterile to a highly sterile environment. The current system experiences a high failure rate, with a success rate of only <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\varvec{30~\%}\)</EquationSource> </InlineEquation> in the initial de-bagging step, leading to significant product loss and production downtime. Through a series of empirical, mechanical, and push-out force-based optimisations, including improvements to the product guide rails, clamping mechanisms, and pusher bar operation the success rate of the de-bagging process was increased to <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\varvec{89~\%}\)</EquationSource> </InlineEquation>. Based on the results a set of generalised recommendations was formalised for the design of other de-baggers. Part of the suggested optimisation methods have since been integrated in a real de-bagger setup, which shows similar results to those achieved in the test setup.</p>

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Optimisation of the Primary De-bagging Step for Double-bag Products Within Aseptic Production Processes

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年2月3日

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  • Gert Schouterden,
  • Ivo Dekker,
  • Anton Melnikov,
  • Rafaël Verbiest,
  • David De Schepper,
  • Eric Demeester,
  • Karel Kellens

摘要

This paper presents a comprehensive optimisation and evaluation of an automated de-bagging process for aseptic manufacturing, where a double-bagged product must be transferred from a non-sterile to a highly sterile environment. The current system experiences a high failure rate, with a success rate of only \(\varvec{30~\%}\) in the initial de-bagging step, leading to significant product loss and production downtime. Through a series of empirical, mechanical, and push-out force-based optimisations, including improvements to the product guide rails, clamping mechanisms, and pusher bar operation the success rate of the de-bagging process was increased to \(\varvec{89~\%}\) . Based on the results a set of generalised recommendations was formalised for the design of other de-baggers. Part of the suggested optimisation methods have since been integrated in a real de-bagger setup, which shows similar results to those achieved in the test setup.