Image credit: DALL.E
When it comes to pharmaceutical injection moldings, the critical importance of cleanliness and precision cannot be overstated.
Ensuring effective mold cleaning is a fundamental component for adhering to the exacting quality standards required in Clean Room environments.
Let’s look at a novel approach that is redefining the methodology for on-press mold cleaning in pharmaceutical Clean Rooms.
The Complexities of Mold Contamination in Clean Room Environments
In the highly sterile environment of Clean Rooms, it is paramount that injection molds stay in a constant state of pristine condition.
During the injection molding process, molds are exposed to a range of complex interactions with various materials and environmental conditions. This leads to the accumulation of different types of residues on the molds.
One of the most critical among these are mold release agents which are commonly applied to remove the molded part from the mold. However, these mold release agents often build up over a period of time.
Furthermore, resin plate-outs (residues from the plastic materials used in the molding process) also accumulate on mold surfaces. These residues can harden and become more difficult to remove as they are increasingly exposed to the high temperatures of the molding process.
Another common issue is the formation of subsequent rusting on the mold surfaces. This can occur due to exposure to moisture or certain chemicals, and while it may seem negligible prima facie, it can have significant implications on the precision of the molded parts.
The removal of these contaminants presents a substantial challenge, especially considering the operational constraints within a Clean Room. The fact that these molds are often still warm and actively engaged in the press when cleaning needs to occur adds an additional layer of complexity.
Warm molds can cause cleaning agents to evaporate quickly or react abruptly, reducing the overall effectiveness of the cleaning process. Moreover, the need to clean the molds without causing downtime or disrupting the production process requires novel solutions that are not only effective but also compatible with the continuous operation of the molding equipment.
In a nutshell, the process of mold cleaning in Clean Rooms is not just a matter of maintaining cleanliness, but also a critical aspect of ensuring the operational efficiency, product quality, and safety in the production of medical devices and pharmaceutical components.
A Novel Approach To Minimise Mold Contamination
The Sahara+ Wiping System is an advanced solution designed to overcome the complexities of on-press mold cleaning in Clean Room settings.
Here is how it helps:
1. Solvent Delivery via Sahara Foam
The Sahara foam, crafted from robust polyurethane sponge material, excels in solvent delivery to heated molds while generating low particles due to its construction.
This facilitates the effective dissolution of mold release build-up and resin deposits, even on warm molds.
2. Scratch-free Scrubbing
The Sahara foam offers a non-abrasive scrubbing action, crucial for removing resins and mold releases without inflicting damage on the mold surface.
This aspect is vital for preserving mold precision and longevity.
3. Seamless Adaptability to Mold Contours
The pliability of Sahara foam enables it to conform to various mold shapes, thereby reaching recessed areas and vents where residues often accumulate. Such comprehensive cleaning ensures the removal of all impurities.
4. Precise Cleaning with MiraWIPE
Post the loosening of residues by Sahara foam, the final cleaning stage is executed using MiraWIPE.
This abrasion-resistant deep cleaning MiraWIPE effectively dislodges, captures, and eradicates residues, ensuring a thoroughly cleaned mold surface.
5. Minimised Particle Generation
Distinct from other cleaning wipes, MiraWIPE’s abrasion-resistant fabric is proven to minimise particle generation during cleaning, thus reducing the likelihood of defective parts.
Summing Up
Maintaining exemplary mold cleanliness is a non-negotiable aspect in Clean Rooms.
The Sahara+ Wiping System represents a significant advancement in on-press mold cleaning, integrating the effective abrasion of Sahara foam with the deep cleaning and durability of MiraWIPE wipers.
This potent combination guarantees that molds are kept in pristine condition, devoid of mold release build-up, resin plate-outs, and other contaminants.
To learn more about how the Sahara+ Wiping System can help you maintain the precise integrity of your Clean Room molds, please get in touch with us at vivek@groverholdings.com.
Credits:
Foamtec International, Wilshire Contamination Control Division
Alsico Iberia S.L. (formerly Vestilab CRC S.L., Spain).