Factory Sealed

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Most of us have seen the familiar site of a new house being constructed. Stacks of materials sitting in the front yard and a small crew of workers cutting and nailing lumber in place to create the framing. What most of us have never seen is the amazing modern high-tech approach to a system built house. The modular industry has perfected methods to create a strong, High Quality house at substantial savings.

Through the use of technology and computer-aided design and computer-aided manufacturing, almost any floor plan that can be site built can now be built in a factory for 15% to 20% less cost, and in far less time. The normal time frame to build a conventional house can be reduced from six-to-twelve months to three-to-four months on most projects.

In a typical construction time line, the framing cannot begin until the foundation is completed and cured. In a modular system format, several work packages can be performed simultaneously to reduce the overall completion time. For instance, while the foundation is being poured, the house is also being built in the factory. Then when the foundation is ready, the house is put together and shipped to the building site where it is then lifted in place on the foundation. This process greatly reduces the time it takes to move into your new house, and as a result reduces the monthly costs associated with a construction loan.

The biggest differences in construction are seen in the factory itself. Walls and floor are built with high accuracy because it is performed in a controlled environment. Specialized machines and tools install the nails and fasteners that bind the structures together. All the material is staged and ready for use in a temperature controlled building, avoiding the damage and warping that often occurs when materials are exposed to the weather at a job site. All the workers are highly trained in the area of their specialty in the assembly and building process.

Because the house will be shipped hundreds of miles and lifted into place with a crane, the house contains 15 to 20% more material. The extra material is needed to maintain structural integrity during the house moving and setting process. Doors and window headers are triple planked instead of double planked. The walls are steel strapped to both the floor and roof trusses. Floors and walls are glued, as well as fastened in place. A double-rim joist instead of a single-rim joist surrounds the perimeter of the house where the sill plate will mount, and the exterior walls are constructed out of 2x6 wall studs instead of the commonly used 2x4 wall studs. All this additional material and attention to detail creates a structure that is much stronger then the conventional residential house.

A testament to modular house structural strength are found in excerpts from the Federal Emergency Management Agency (FEMA) report after the 1992 Hurricane Andrew in Florida. The Building Performance: Hurricane Andrew in Florida report found "Overall, relatively minimal structural damage was noted in modular housing developments. The module-to-module combination of the units appears to have provided an inherently rigid system that performed much better than conventional residential framing." The report also noted that modular homes withstood the ravages of that storm's Category 4 winds of 131-155 mph far better than site-built housing.

The differences between a modular and conventional home from an energy efficient standpoint are distinct. A modular home wall construction is foam sealed to prevent air leaks. Depending on the geographic location and the local building code requirements, walls can be insulated with an R-21 value and the roof can be insulated with an R-60 value. The R-value measures the insulation's ability to resist heat traveling through it. The higher the R-Value the better the thermal performance of the insulation. It is common to have a 30% reduction in heating cost in a modern modular home.

It is little wonder that so many purchasers are looking closer at the cost savings option of having their next house be system built. All of these differences equal a house built to the highest standards, delivered in less time, saving the homeowners time and money. Modular Homes have become the leading edge choice in high-tech, energy efficient construction.

S. Hartman works for Oasis Homes, LLC, a custom modular home manufacturer specializing in ranch, cape, two story, multi-family and light commercial structures. Oasis Homes serves counties in southeast Michigan. http://newoasishomes.com/ For More Information call Toll Free (877) 95-OASIS or email customercare@newoasishomes.com.

Cipla Gives Seal Of Approval For Oel Level 5 Sieves

Sieves are an integral part of most pharmaceutical processes and usually with the primary role to ensure ingredients and finished products are quality assured during production and before use or despatch. When processing active pharmaceutical ingredients (API’s), the occupational exposure limit (OEL) has a significant part to play in the design of a process to ensure operators are not at risk to exposure. Therefore when Cipla Ltd built their OEL compliant plant at their Goa factory in 2005, having sieves that would ensure product quality and integrity were maintained without compromising the safety of their operators was essential.

 

In recent years, the pharmaceutical industry has seen a growing demand for products that require API’s and with the introduction of highly potent API’s (HPAPI’s), the concern for operator’s safety due to the adverse effects related to the handling of dangerous compounds is becoming more prevalent. Although a range of personal protective equipment (PPE) is widely available, this can only reduce exposure levels rather than eliminate them. Therefore, having certified plant equipment that can help reduce OEL levels must be considered an advantage not only to improve the working environment of operators but also to reduce costs associated with sophisticated PPE and dust containment systems.

 

Cipla’s new OEL compliant plant was built for the manufacture of a new highly potent drug and as with nearly all processes handling pharmaceutical powders, to ensure specification and quality were upheld a number of sieving operations were required. Firstly, on incoming raw materials to remove any oversized contamination and secondly after granulation to remove undersized particulates.

 

It was the task of Tapas Datta, factory manager of Cipla plant in Goa, to source suitable sieves to meet their stringent requirements. Due to the vibrating action of sieves, dust can be generated very easily and therefore the need for high containment sieves was required. It was during its showcase at an exhibition in 2005 when he came across the OEL level 5 sieve offered by Russell Finex. Known as the Compact

Airlock Sieve®, it utilizes a pneumatic clamping system, which, combined with its patented Twist Lock Inflate (TLI) technology, provides a uniform dust tight seal. “We were unable to find a sieving unit anywhere else with this level of containment†explains Tapas.

 

The unit is clamped together with a revolutionary airlock system.  The pneumatic lock gives an even and high clamping force across all sealing faces and therefore guards against powder leakage more effectively than traditional band clamps or over-centre toggle clamps. Through independent tests this valitable clamping system has been certified to an OEL value less than 1µg/m3 (OEL level 5).

 

The relationship between Russell Finex and Cipla started in 2001 after purchasing their first sieve. To date, the Goa site has multiples of Russell sieves positioned in a variety of production lines carrying out various check screening and grading applications. “During initial product trials, we recognised how the new Airlock sieves utilise the Russell Compact technology to increase screening efficiency allowing even sticky products to be sieved without blinding†Tapas adds, “Also, due to its new clamping system, it is extremely easy to dismantle when compared to conventional clamping methods.â€

 

Assembly and disassembly of the sieves are achieved in seconds.  The component parts are placed into the base and located by twisting and locking the lid without the need for tools.  The airclamp is then inflated to secure and seal the unit during operation. The unit is suitable for either continuous or batch operations and also lends itself to applications where a number of different products are being processed due to the simplicity and speed with which it can be disassembled and cleaned.

 

The plant has been in operation for over 3 years and Cipla have been looking at ways to improve the process further. Although the cGMP design of the sieves is based on clean lines making sanitation easier, reducing the exposure of operators to products during clean down of the sieves can be achieved by retrofitting the Russell WIP system. This spray ball system allows an even spray on the product contact parts to wet the components prior to dismantling the sieves, improving handling of the components during clean down. Tapas concludes, “We would always prefer to purchase Russell sieves due to their high quality design, finish and performance. It is clear that this particular unit has been designed specifically for this type of application.â€

 

For over 75 years Russell Finex have manufactured and supplied filters, sieves and separators to improve product quality, enhance productivity, safeguard worker health, and ensure liquids and powders are contamination-free. Throughout the world, Russell Finex serve a variety of industries with applications including food, pharmaceuticals, chemicals, adhesives, plastisols, paint, coatings, metal powders and ceramics.

About the Author

Russell Finex assure and enhance the reputation of companies in almost every process industry throughout the world. We achieve this by manufacturing and supplying sieves and filters to improve your product quality and ensure your powders and liquids are free from contamination.

 

Russell Finex Ltd, Russell House, Browells Lane, Feltham, Middlesex, TW13 7EW, England,

Tel.: +44 (0)208 818 2058,

Fax.: +44 (0)208 818 2060,

Email: enquiries@russellfinex.com

www.russellfinex.com

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