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IBCs for Collecting Lots in Pharmaceutical Manufacturing

With IBCs up to 3500L capacity, the Matcon IBC system gives pharmaceutical manufacturers the flexibility to collect lots efficiently. One granulation lot or multiple lots can be consolidated into a single IBC.

This approach in using large IBCs for collecting lots reduces the total number of containers needed to run the process, which means fewer IBC movements, fewer make-and-break connections, shorter testing cycles and less cleaning time. The result is a leaner, more productive manufacturing operation with lower labour demands.

How Does the IBC System Reduce Labour in Pharmaceutical Manufacturing?

Handling tablets and granules in larger batches in a single large IBC directly reduces the amount of labour needed to keep the process running. Fewer IBCs in circulation means fewer connections to make and break, less time spent moving containers, and fewer cleaning cycles between batches.

One operator can manage a process step that would previously have required multiple people. This frees up skilled staff to focus on quality checks and higher-value tasks rather than routine container handling.

For manufacturers under pressure to improve productivity without expanding headcount, this is a measurable operational benefit. You can see how this works in practice on the pharmaceutical manufacturing best practice page.

Related Pages

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Collecting-Lots
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Why Use Large IBCs for Collecting Lots?

Using large IBCs for collecting lots is a proven lean manufacturing strategy. By consolidating multiple granulation lots into one container, you cut down on the number of process steps, container transfers, and operator interventions.

Fewer movements across the production floor means less risk of contamination and fewer opportunities for errors. This directly improves your Overall Equipment Effectiveness (OEE) and reduces the cost per batch.

Does Collecting Lots in One IBC Maintain Product Consistency?

Collecting and homogenising lots after drying gives you confidence in product consistency across all the batches.  In the past, large IBCs presented problems with powder flow, including bridging and rat-holing, which made reliable discharge difficult. Matcon's IBCs solve this through the Cone Valve technology built into every bin. The Cone Valve delivers controlled, automatic discharge of material and actively prevents mix segregation, so your blend uniformity is protected through to discharge.

How Does the Cone Valve Protect Blend Integrity?

The Matcon Cone Valve is the key to reliable powder flow in large-capacity IBCs. As the valve opens, it creates an even mass flow pattern across the full cross-section of the IBC, preventing the formation of channels or dead zones that cause segregation. This means the powder that enters the IBC exits in a consistent, predictable way, regardless of batch size or powder characteristics.

For pharmaceutical manufacturers where blend uniformity is a regulatory requirement, this level of control is essential. Learn more about our Cone Valve technology here.

Key Features of Collecting Lots into Matcon IBCs

The Matcon IBC system for collecting lots is built around flexibility, hygiene, and process efficiency.

  • Large IBCs up to 3500L available for combining large Lots
  • Blending takes place within the IBC itself even on large IBCs
  • Closed filling below the dry mill for dust-free, contained operation
  • Check weighing options to support batch accuracy and traceability
  • Single-floor or through-floor configurations to suit facility layout
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Related Resources

Click on any of the assets below to request a .pdf copy.

OSD Pharma Brochure

IBC Brochure

Cone Valve Technology Brochure

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WHITEPAPERS

A Better Way To Handle Tablets Using IBCs

Handling tablets in larger batches using IBCs reduces the amount of labour needed to move containers and make and break connections at each stage of the tablet finishing process. Fewer transfer events mean better control, stronger traceability and recording throughout tablet processing.

A single Tablet IBC can replace multiple drums and offers automatic filling capabilities, while reducing the risk of breakage or damage during transfer. For operations running high volumes of tablets, moving from drums to IBCs at the tablet handling stage delivers measurable improvements in throughput and production efficiency.

Download the Brochure

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Frequently Asked Questions About Combining Lots in One Large IBC:

Collecting lots refers to the process of combining one or more granulation lots into a single IBC container after drying.

This consolidation step reduces the total number of containers in use, cuts down on transfer steps, and helps ensure product homogeneity before blending. It is a standard lean manufacturing practice in oral solid dose pharmaceutical production.

Matcon IBCs are available in capacities up to 3500L, making them suitable for collecting single or multiple granulation lots in one container. We have the ability to make bespoke IBCs with reduced height to ensure they fit into your facility. 

This large capacity reduces the number of IBCs needed across the process, which lowers handling time, cleaning requirements, and overall operational complexity.

The Matcon Cone Valve technology ensures controlled, even discharge of material from the IBC. This prevents channelling and segregation during discharge, protecting blend uniformity.

The cone valve design creates mass flow conditions that keep the powder moving consistently, regardless of particle size differences within the blend.

The Matcon system can be designed to include check weighing options that allow operators to verify batch weights at the point of collection.

This supports accurate lot management, batch traceability, and compliance with pharmaceutical manufacturing records. Integrated weighing reduces manual data entry and the risk of human error in batch documentation.

The Matcon collecting lots system can be designed as both a single-floor and through-floor configuration.

A through-floor setup uses gravity to transfer material from the milling level on one floor down into the IBC on the floor below, which reduces the need for mechanical lifts and lowers energy use.

A single-floor configuration keeps everything on one level, where height allows or where a phased expansion approach is planned.

Both options deliver the same high standard of containment and blend uniformity integrity. If you are planning a new pharmaceutical facility or upgrading an existing line, the single vs two-floor pharmaceutical facility guide covers the key considerations in detail.

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