Telstar, part of the azbil Group, is an international leader in the development of high-technology solutions for the pharmaceutical and biotechnology industries, has developed two Safety Airlock System (SAS) units with volumes of more than 5m³.

Each one of the SAS units fitted with integrated ionHP (ionised hydrogen peroxide) bio-decontamination systems, have been developed to be installed between two zones with different grades in Virbac’s aseptic manufacturing facility.

Although Telstar has experience in the installation of bio-decontamination systems into Isolators, it has successfully adapted this type of bio-decontamination system for use in a SAS; for transference of materials into aseptic installations.

The SAS units developed by the Technology Centre for Barrier Isolation Systems within Telstar, located in Dewsbury (UK), are designed to sanitise materials that are not suitable for sterilisation by other methods and are capable of bio-decontaminating a fully laden unit, in less than 2 hours while achieving a log 6 reduction in bio-burden, validated using a bio-indicator (BI) challenge. The 2 hour cycle duration is inclusive of aeration down to a level of <2ppm H2O2 while working independently to the facility’s HVAC system.
 
Using the innovative integrated ionHP bio-decontamination systems were key factors for the transfer systems as they provide a cost effective and efficient way of bio-decontamination with reduced cycle times when working independently to the facility’s HVAC system.
 
Reduced cycle times are achieved because the ionHP bio-decontamination efficiency is not effected by temperature and humidity and thus the need to pre-condition the chamber prior to injection is eliminated. The method of injection causes immediate disassociation of the liquid solution to produce hydroxyl radicals, ROS, O3, RNS, plasma, UV and heat activation providing synergistic effects of multiple antimicrobials.
 
Finally, the EPA registered sterilant used has a lower concentration of H2O2; 7.5% compared with conventional vapour-phase bio-decontamination systems which can be as high as 30%-35%. This reduced concentration improves material compatibility and sterilant usage is reduced, giving savings in operational costs for sterilant consumption.
 
Following the successful completion of this innovative project, Warren McFee, engineering manager at Telstar UK commented, “The project proved to be very rewarding, involving Telstar’s project management team working alongside the client to meet their specific requirements”

Founded in 1968 in Carros close to Nice by veterinarian Pierre-Richard Dick, Virbac is dedicated exclusively to animal health. With a turnover of €736 million in 2013, the company ranks today as the 8th largest animal health company worldwide. Its wide range of vaccines and medicines are used in the prevention and treatment of the main pathologies for both companion and food-producing animals.