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Systag FlexyPAT: Automation Technology for Chemical Process Lab

Ken Kimble Ltd has a long history of supplying and supporting not only simple stirred-vessel systems, but also those incorporating automation (for hydrogenation, parallel synthesis and azeotropic distillation etc). We are now excited to introduce FlexyPAT – a combination of hardware and software which enables you to automatically perform and monitor your chemistry. The FlexyPAT is designed and manufactured in Switzerland by Systag – a respected partner in the pharmaceutical industry for over 50 years and a market leader in automation solutions for all aspects of chemical process development.FlexyPAT Automated Reactor with tablet

A key feature of the FlexyPAT is that you are able to utilise your existing reactor vessels, heater/chillers, pumps and balances; this not only reduces the cost but familiarity of the equipment accelerates system acceptance.  Of course we can also supply a ‘Turn-Key’ solution that includes all the relevant equipment for your process.

At the heart of the FlexyPAT is a module to which all the relevant reactor system parts are connected, very much in a ‘plug and play’ manner. This includes the heater/chiller, stirrer motor, balance(s), syringe pump(s), dosing pump(s) and online sensors (such as turbidity, midIR, FTIR, particle size, pH and temperature). There is even the ability to automatically take photographs of the vessel contents at either set times or when, for example, the turbidity has reached a certain value. FlexyPAT uses cable recognition technology allowing sensor devices to be instantly recognised when connected.

A PC is loaded with FlexySys application software and this in turn is used to control and monitor the FlexyPAT and therefore your reactor system.

The system is very flexible in terms of being able to integrate both existing equipment and additional devices either at the start or later on as your future chemical processing dictates. Not only can ancillary equipment such as dosing pumps be added but up to five additional complete reactors can be controlled from a single FlexyPAT module.

The FlexySYS software will allow the operator to control the reactor remotely either on-demand or to set up and run complex ‘recipes’ with multiple steps.

These recipes are very easy to prepare using the ‘drag-and-drop’ method with a built-in logic check. More than a simple series of steps, a recipe can include loops and jumps to be set up in response to certain recorded values. This feedback from the sensors enables not only something as simple as pH control but also the temperature could be controlled in response to turbidity, for example. A very useful feature is a Hold step which can be used to take a sample for analysis.

The user-friendly control screen presents an animated depiction of the hardware in use and the operator is simply able to click on each device and control it. In terms of Process Development an important feature is that the settings, operations and analytical measurements are stored automatically and compiled as a batch record.FlexyPAT Automated Reactor Control Software

With the appropriate hardware in place, the FlexyPAT is able to control the following:

…and the following data can be monitored/calculated and stored:

In addition to the above, the FlexySYS software includes a set of easy-to-use programmes which enable you to perform calibration of the PT100 and pH probes as well as the PID settings for the temperature control circuit. A record of these actions can be appended to your batch record.

Should you decide to source the reactor itself from us we offer the especially designed FlexyPAT Caddy which has a jacketed glass (or metal) vessel (various volumes available)held within a stainless steel frame and base. It is designed to sit on a bench within the fume cupboard but if you have a walk-in FC or you would like to be able to easily remove it and store elsewhere we will also supply the FlexyPAT Trolley onto which the Caddy can be positioned and locked in place. The frame of the Caddy is cleverly designed to support the FlexyPAT as well as various hardware devices such as pumps, probes and the stirrer motor whilst hiding the cables and giving the operator maximum access to the vessel and lid. Alternatively, if you already have support framework at the back of the fume cupboard we can utilise this instead.

Typical areas of application for the FlexyPAT are the following:

Whether you are looking for a complete Turn-Key automated reactor system or a means to control your existing equipment please call us to discuss your process and we will customise a system for your needs.

Date posted: 14-01-2016