In this webinar, Scott Patterson, Vice President of Technical Sales, PharmBio at ILC Dover, will introduce the DoverPac® FIBC, a high-containment system designed for safe, efficient powder transfer in pharmaceutical processes. DoverPac’s single-use design eliminates cleaning requirements, delivering significant cost savings and production efficiencies. Its flexible wall technology ensures superior mass flow and complete discharge, even with challenging powders, minimizing product retention. Join this webinar to discover how DoverPac technology supports high-containment, reliable performance across various applications. Watch the video or explore the transcript below to learn more.
Transcript
Introduction
[Scott Patterson] 0:00
I am Scott Patterson, Vice President of Technical Support for the PharmBio business at ILC Dover. I’ll be your presenter today, introducing DoverPac, a technology designed for handling highly potent active pharmaceutical ingredients and facilitating transfers in the pharmaceutical process. We’ll focus on several benefits of DoverPac technology, with two key advantages being its superior powder flow properties and zero cleaning requirement due to its single-use technology.
In this presentation, we’ll cover a summary of DoverPac technology, which serves as a high-containment system that goes beyond simple powder transfers. It’s capable of high containment, with proven performance data we’ll review using the SMEPAC protocol. Key features include superior powder flow from a mass flow concept and zero cleaning, leveraging single-use technology. We’ll also discuss time and cost savings when comparing DoverPac technology to IBC and split butterfly valve systems, present a few common pharmaceutical workflow examples, and wrap up with a summary.
Doverpac Design
[Scott Patterson] 1:37
DoverPac technology provides more than just containment; it was purpose-designed for handling pharmaceutical products rather than repurposing common super sacks or big bags. Around 1996, with more potent drug compounds emerging, pharma manufacturers came to ILC Dover seeking improved containment and cost-effective alternatives to durable stainless-steel containment devices. Requirements included containment to less than one microgram per cubic meter, handling of both dry powders and wet cake, and managing large batch sizes exceeding 5000 kg. In-line containment sampling was also needed to avoid breaking containment for sampling. This single-use technology had to be resistant to solvents and static and meet FDA and other global compliance standards, all without requiring cleaning.
The DoverPac technology operates through a straightforward process of connecting, clamping, opening, using, sealing, and disconnecting the DoverPac, repeated in a consistent, operator-friendly sequence. The system starts with a patented O-ring canister, a stainless-steel reusable device connected via tri-clamp. After filling, the seal and separate process is completed, and the DoverPac moves to the next operation. If multiple DoverPacs are needed, a stub end is used to connect the next pack, which is removed through a bag-out process, allowing a repeatable workflow.
DoverPac technology incorporates an ArmorFlex liner inside a conductive polypropylene restraint, providing high strength, static dissipation, and solvent resistance. This meets global product contact standards and has passed stability trials for numerous molecules over 25 years. The system is also UNDOT-certified for global transport, undergoing rigorous drop tests to prevent failure. A high-containment sampling sleeve was integrated to allow in-line sampling at any process stage, keeping operators safe and ensuring sample integrity.
Containment Performance
[Scott Patterson] 6:55
One of the primary design philosophies for DoverPac was “contain at the source,” meaning keeping powders in the process to avoid environmental contamination and minimize risk to operators. Instead of using ventilation systems that transfer risk to other areas, the DoverPac includes a reliable sealing mechanism with the crimp lock system, allowing it to remain closed during transfer. This design protects operators and the environment, eliminating dust leakage and facilitating easy disposal after use.
High containment performance is supported by robust data. For example, containment tests using lactose as a surrogate yielded results below 30 nanograms per cubic meter during filling and around 130 nanograms per cubic meter during discharge. This demonstrates DoverPac’s capability to consistently operate below 150 nanograms per cubic meter, depending on factors like particle size and powder type.
Other Critical Advantages
[Scott Patterson] 12:30
DoverPac also provides mass powder flow advantages, with a wide 200-300 mm neck diameter enabling efficient flow without the valve obstruction typical of split butterfly valves. This feature, coupled with flexible wall construction, allows operators to discharge powder fully and easily, minimizing product retention. Tests indicate less than 0.05% powder retention after discharge, a marked improvement over stainless steel IBCs where up to several kilos of powder can be left behind.
As a ready-to-use and quickly disposable system, DoverPac minimizes cleaning needs entirely. When filled and discharged as needed, it requires no floor space for storage. After discharge, it is crimped and ready for disposal, generating minimal plastic waste compared to the substantial rinse water and chemical waste associated with cleaning stainless steel IBCs. DoverPac disposal involves only a few kilograms of plastic, while cleaning a stainless steel IBC can produce up to 500 kilograms of waste.
The cost equation for using stainless steel technology includes high capital expenditures for stainless steel IBCs, split butterfly valves, post lifts, and bin washers, all of which take up valuable floor space, require maintenance, and lead to lost production time during cleaning validation. In contrast, DoverPac’s single-use design avoids these costs and enables continuous production, even when switching between different drug products.
Workflow Applications
[Scott Patterson] 19:28
DoverPac is widely used in pharmaceutical workflows, including chemical synthesis for handling both non-potent and potent APIs across various stages, such as reactor charging, centrifuge discharge, and dryer loading. This closed-system approach ensures high containment throughout the process.
Another workflow application is conical milling, where DoverPac facilitates high containment for milling or de-lumping powders. In these setups, flexible isolators are used to contain powders transferred from drums into mills under high containment, with tested containment levels often below 50 nanograms per cubic meter.
Conclusions
[Scott Patterson] 22:07
In summary, DoverPac is purpose-built for the pharma market as a high-containment transfer system. With a large open neck and flexible wall, it enables complete discharge with minimal product retention, reducing costs, floor space, and production downtime associated with cleaning. DoverPac supports efficient, high-containment workflows across both chemical synthesis and oral solid dosage processes, making it a valuable tool for modern pharmaceutical facilities.
Thank you for spending time with us today. You can visit our website at www.ilcdover.com, where a contact form is available for questions and inquiries. We’ll respond to you as quickly as possible. Thank you very much.
