Multi-Plant

Summary

TOYO's Multi-Plant concept proposes advanced solutions for batch process plants where small quantity and various types of products are produced (variable-type variable-volume production) with extensive and consistent application of proprietary technologies.

Features

TOYO offers the optimum system to meet client's needs such as the pipeless production system, "MILOX®", or the automated line changeover system, XY Router®.
The XY Router, eliminating cross contamination and flexibility. in particular enables flexible and contamination-free operation. Also, the quantity of the pipe decreases making the plant costs less. Multi-Plant contains a built-in automatic cleaning system to ensure constant cleanliness quality.
Linking the Multi-Plant with production management software, scheduling software and other software enables optimum batch plant design and operation to be realized. We prepare the plant layout and zoning plans to meet the quality level required for the Multi-Plant. This enables, for example, a multi-plant engaged in active pharmaceutical ingredients to handle GMP and achieve efficient production at the same time.

Production system using flexible module arrangements

At a batch plant, a container, mixer, condenser and other simple functions are considered as a module (unit), and the processing system is configured by combining the modules. These combinations make it possible to engage in diverse processes, such as reaction, extraction, crystallization and dissolution. The method of creating a new production system by rearranging these modules is referred to as a production system using flexible module arrangements. The system enables enhanced flexibility at the production site. This idea and this system is very effective in optimizing plants engaged in producing small volumes of different types of products.

Tems required by a Multi-Plant engaged in producing small volumes of different types of products.

Flexibility with regard to produced items
Flexibility with regard to volumes handled
Flexibility with regard to changes in manufacturing processes
Simple, standardized cleaning at the time of switching
Simplicity in the duct system
Simplicity and flexibility in the control systems

The production system using flexible module arrangements is a methodology for solving these issues.

Specific forms of the production system using flexible module arrangements that supports Multi-Plants

MILOX with mobile tanks and containers
XY Router with mobile pipes and stationary tanks

We have proposed the optimum production system to suit the production scale, style and required quality levels at the plant. We have also developed and verified element technologies for both hardware and software, as common tools for configuring different systems.

Schemes for the production system using flexible module arrangements

Multi-Plant domain

A diverse range of solutions are presented, with a fixed/mobile tank (boiler) as one parameter and the nature of the fluid bodies handled as another.

Flow diagram for the proposed solution

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※	MILOX is a registered trademark of Toyo Engineering Corporation in Japan.
※	XY Router is a registered trademark of Toyo Engineering Corporation in Japan.