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Resolving Electrostatic Adhesion in Capsule Handling Using Flexivalve with Conductive EPDM

  • maio 11, 2025

Background: Our client contacted our team after facing issues during the transfer of capsules for tablet production. These capsules tended to stick to the silicone-coated disc of the Flexivalve, used as a shut-off valve, due to static electricity generated by the capsule flow. The Flexivalve, made of stainless steel with a silicone-coated disc, is an optimal solution for regulating the flow of delicate products in pharmaceutical, chemical, and food industries. However, the client’s specific challenge involved using empty capsules which, due to their significant air volume relative to weight, became statically charged when in contact with silicone, causing them to stick to the elastomer.

Issue Identification: Static electricity and the resulting capsule adhesion to the silicone disc during discharge posed a major issue in pharmaceutical production.
This problem caused production interruptions and delays, increased downtime and operating costs. Adhesion could lead to product contamination, dosing variations, and non-compliance with GMP regulations, thus affecting final product quality and safety. Delays in supply negatively impacted the production chain and overall efficiency.

Proposed Solution: The proposed solution was to replace the silicone-coated disc with a conductive EPDM-coated one to reduce capsule adhesion. This solution effectively dissipates static charges, preventing capsule sticking. The conductive EPDM butterfly minimizes electrostatic buildup on the valve surface, allowing smoother capsule flow through the Flexivalve.

Implementation Steps

  • Evaluation and Selection: A conductive EPDM compound suitable for the application was identified, ensuring compatibility with industry standards.
  • Production Process: A process was developed to manufacture the conductive EPDM disc with precise dimensions and uniform conductivity.
  • Testing and Validation: Extensive testing confirmed the effectiveness of the EPDM disc in reducing electrostatic-induced capsule adhesion.
  • Installation and Integration: Only the silicone disc of the butterfly valve was replaced with the conductive EPDM version, preserving valve functionality.
  • Training and Support: The client’s staff was trained on operation and maintenance of the modified Flexivalve, with emphasis on proactive measures against static-related issues.

Benefits

  • Improved Production Efficiency: Reduced downtime and capsule sticking led to increased overall productivity.
  • Enhanced Product Quality: Lower risk of contamination or damage ensures consistent, compliant product quality.
  • Customer Satisfaction: Proactively resolving the adhesion issue demonstrates a strong commitment to long-term customer relationships.

Conclusion: By replacing the silicone disc with a conductive EPDM one, the client effectively eliminated capsule adhesion issues in the Flexivalve, improving both production efficiency and product quality.

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