Major Pharmaceutical Firm Boosts Efficiency with Elios 2 for Tank Inspections

A significant pharmaceutical company recently utilized the Elios 2 drone to conduct critical tank inspections tied to Riboflavin testing. Here's what they discovered about this innovative approach.

Key Benefits at a Glance

Introduction

Large-scale tanks are essential in pharmaceutical manufacturing, typically constructed from stainless steel for its superior cleaning properties. These tanks must remain spotless throughout production cycles.

Following each production run, tanks undergo rigorous cleaning with acids and alkalis. However, whenever a new tank arrives or a revised cleaning protocol is introduced, health and safety teams must confirm that the tank is free of all contaminants and that future cleanings will be effective.

This verification process involves spraying Riboflavin, a fluorescent substance, onto the tank walls using a long rod. The Riboflavin adheres to the surfaces, allowing inspectors to assess the efficacy of the cleaning procedures. Once applied, the Riboflavin is removed to verify the success of the cleaning protocols. This method is known as a Spray Shadow test or Riboflavin test.

Riboflavin inside a tank

Riboflavin serves as a substitute for potential contaminants, making it easier for personnel to determine whether their cleaning methods are truly effective. If any Riboflavin remains after cleaning, adjustments must be made, and the process repeated until no traces remain.

Typically, two entries into the tank are necessary: one after applying the Riboflavin to confirm full coverage, and another after cleaning to ensure all traces are gone. During these entries, workers use UV lights to illuminate the Riboflavin, verifying both coverage and cleanliness.

Customer Requirements

A major pharmaceutical manufacturer operates several large tanks at a facility in Austria.

A production tank at the manufacturing site

The company sought ways to accelerate their Riboflavin tests to minimize downtime and enhance cost-efficiency. Additionally, they aimed to conduct these inspections remotely, eliminating the need for personnel to physically enter the tanks.

AEROVISION Drone Support GmbH Offers Cutting-Edge Solution

Markus Rockenschaub of AEROVISION Drone Support GmbH, a drone inspection service provider based in Austria, suggested testing Flyability’s Elios 2 for the upcoming Riboflavin inspections.

Designed for confined space operations, the Elios 2 was deemed ideal for navigating these tanks and capturing high-quality visual data.

Outcomes

Rockenschaub successfully collected all necessary visual data for the Riboflavin tests using the Elios 2, completing inspections on five tanks in a single day. With the help of a large monitor, he live-streamed footage from the drone, replacing manual entries with remote drone operations.

First, he flew the Elios 2 into the tank after Riboflavin application to ensure full coverage. Later, after cleaning, he repeated the process to confirm no Riboflavin remained.

Live-streamed data from the Elios 2 inside a tank

As a result of AEROVISION’s trials, the pharmaceutical company experienced the following advantages:

• Economic Gains: Reduced downtime saved the company 60,000 Euros.

• Time Efficiency: The total time spent on five Riboflavin tests dropped from ten hours to four.

• Safety Improvements: Personnel no longer needed to enter the tanks.

• Workforce Optimization: The number of inspectors required decreased from five to three.

Notably, the drone detected residual Riboflavin in some cases, requiring additional rounds of cleaning. While this is standard, traditional methods might have caused prolonged downtime because personnel would need to physically re-enter the tanks.

Elios 2 footage revealing trace Riboflavin residue

Conclusion

Encouraged by AEROVISION’s trial outcomes, the pharmaceutical firm plans to integrate the Elios 2 into more of their tank inspections. Additional tanks are set to arrive at the facility over the next six months, necessitating further Riboflavin tests where the drone could prove invaluable.

Furthermore, the company is curious about the possibility of equipping the Elios 2 with UV lights, enhancing visibility during Riboflavin inspections. This innovation could offer even greater precision and efficiency in their testing procedures.

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