Telstar has built the most advanced space simulation chamber in the south hemisphere

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1 April Number 19 VACUUM Telstar has built the most advanced space simulation chamber in the south hemisphere Telstar has designed and developed the most advanced space simulation chamber in the South hemisphere. This chamber will enable trials of complete satellites to be carried out here on earth under thermal and vacuum conditions equivalent to those that the satellite will experience once it is in orbit around the earth. This project has been carried out under the direction of the INPE (Instituto Nacional de Pesquisas Espaciais), space investigation center, which is under the governance of the Ministry of Science and Technology in Brazil. The installation will enable simulation of the extreme temperatures experienced in space in order to test the operation of the various systems of the satellite as well as the degradation of the materials in the environment of space. The space simulation chamber that Telstar has built for the INPE is in the shape of a tunnel or a mailbox with internal measurements of 7min width, 8.5 m in height and9mindepth with a total 3 internal volume of 485 m. Its main functional characteristics are an ultimate vacuum level of -7 1x10 mbar and the temperatures control range from -180 C to +150 C working with nitrogen gas in the thermal panels (shrouds), or up to -196 C when flooding the shrouds with liquid nitrogen. This data acquisition system has 1500 channels for recording and analysis of the experimental data. By controlling different temperature settings in each of the 6 zones of the thermal shrouds in the chamber, an environment that simulates the conditions of temperature found when the satellite is maneuvering in orbit around the earth can be created, providing the engineers and designers with vital information of the behavior and functionality of the satellite before launch. On the 12th of September, 2008 chamber operational testing was successfully concluded in Brazil. Space conditions In space, far away from the terrestrial surface, the -13 pressure is around 1x10 mbar and the temperature to which the satellite will be submitted (depending whether or not it is receiving direct solar radiation) can vary between 650K (377 C) and 4K (-269 C). Direct solar radiation can be considered constant, but the radiation from the earth and reflected energy from the Sun vary depending upon the meteorological conditions as well as the position and height above the surface. In addition to this visible and infrared radiation there is also present electromagnetic radiation and various particles with a range of intensity and velocity. These environmental conditions are so complex and variable that their simulation on earth is technologically unfeasible, therefore space simulation chambers usually limit tests to vacuum -5 conditions of the order of 1x10 mbar, and those of temperature in a range from -100 C to +70 C. The simulator developed by Telstar reaches Space simulation chamber in Brazil -7 vacuum values of the order of 1x10 mbar and temperatures of -196 C to +150 C, far beyond than the majority of conventional systems. Telstar Technology Telstar's activities in the space industry are focused on projects involving design, development and construction of simulation chambers which combine cryogenic technologies and high vacuum. Among others, Telstar has developed and supplied space simulation chambers for INTA, EADS-CASA (Construcciones Aeronáuticas SA), Thales Space (previously Alcatel Space) and the University of Alcalá. Editorial. Constant professional training and innovation, key factors in strategic business development Telstar Group. Telstar promotes vacuum technology research in collaboration with the UPC. We welcome Life Science Solutions LABORATORY. High containment biological safety cabinets HOSPITALS. Telstar promotes Vertical Laminar Flow technology for the prevention of infection in the operating theatre PHARMA. New Telstar Technologies sterilization facility for BD in Mexico Vacuum Solutions. Telstar leak test station for EADS. Intraoperative radiotherapy equipment based on a 12 mev race-track microton Exhibitions and Conferences BACK COVER

2 EDITORIAL Constant professional training and innovation, key factors in strategic business development Constant adaptation to a changing market forces us to consider technology to be of strategic value in innovation and productivity improvement to knowledge and continuous professional training. Likewise we should be able to identify the competitive advantage in our human resources and in the enterprising leadership in all fields that can deliver added value. Telstar, an industrial group, has invested its efforts in professional training and in R&D since its origin. This has positioned us in the top of the range of businesses in our sector. The simplest thing to do in situations of recession, such as the one we find us immersed in at present, would be to reduce these types of expenses with the clear intention of increasing the benefits to the company. Within the Telstar doctrine this would be a huge mistake. We believe that education is a fundamental part of the growth strategy of our company. Professional training as an investment enlarges the professional value of our workers and, therefore, the value of the business. Through this tool we must prepare our people for the immediate future. Learning the new technologies that, from day to day, arrive on our doorstep and the improvements on which we have already spent years working, will enable us to be a proud workforce far above average. In addition, this tool encourages the emergence of talented individuals from within our organization, who we need to identify with the intention of motivating their desires and guaranteeing their professional growth. We require a flexible and skilled team with the ability to adapt to continuous evolution, since this in the end, is the key value within our business. On the other hand, investment in R&D, either in new products or in new production processes that should increase our efficiency in the design and production of our teams, should guarantee the competitiveness of the company without compromising quality. Expertise and know-how contribute to the international recognition of the Telstar brand and to its association with high technology; encouraging us to continue our belief in innovation and the development of new technologies for the life sciences fields, the strategic sectors and the sciences. The Telstar Group continues to be faithful to its strategy of growth and it is now, in these moments of economic uncertainty, that we offer the best of ourselves to help us achieve Pole Position on the grid. Being in such a position will allow us to continue to have a clear advantage on the day that the markets reemerge along with the international economies. Jordi Peñarrubia, Executive Director TELSTAR GROUP Telstar promotes vacuum technology research in collaboration with the UPC Telstar and the Universitat Politècnica de Catalunya (UPC) have launched an academic and professional programme in vacuum technology and innovation in order to raise awareness, perform research and train new, specialist professionals in the techniques of vacuum, sterilization and air ultra-filtration. These technologies have a multitude of applications in industries linked to life sciences, research and in progressive sectors such as aeronautics, aerospace and the energy industry. Through the involvement of researchers and teaching staff from the School of Industrial and Aeronautic Engineering of Terrassa (ETSEIAT), the Telstar course offers a work programme with teaching, research, development, innovation and technology transfer goals. As such, the target for the Telstar course is to develop combined lines of research in, for example, the modelling of airflows in sterilization ovens and, along with ergonomic optimization, in laminar flow cabinets. Within the scope of the course, Telstar will support the development of final academic projects and doctoral theses in topics that benefit the development of vacuum technology applications. Further, Telstar will offer support for the completion of studies designed to improve the characteristics of its various products. With respect to teaching, educational cooperation agreements will be promoted so that students can undertake professional work placements within Telstar and a series of courses and seminars in this specialist area will be organised for both students and professionals. Additionally, Telstar and UPC will promote national and international meetings concerning topics of scientific and industrial interest and will develop synergies for participating in research projects at local, national and European levels. Finally, Telstar, who will be sponsoring and actively participating in forums developed within the UPC, will award a prize to the student with the best academic record at the Terrassa Engineering School. Telstar enjoys very close ties with engineering training programmes, particularly those of the UPC. In fact, 35% of the company's team of professionals have engineering degrees and 42% of the engineers that work in Catalonia studied at the UPC's Terrassa campus, where the Telstar course is based. In partnership the UPC and the company have entered into projects investigating clean air and cooling technologies for industry, fluid behaviour within new biological safety cabinets, and the development of new industrial th. Agreement signature, November 6, applications based on the use of optical systems for automating the freeze-drying process. The Telstar course in vacuum technology and innovation was launched this academic year following the signing of the agreement on the 6th November 2008, in a ceremony that was well represented by members from the company and the institution.

3 TELSTAR GROUP We welcome Paul Valerio Telstar continues to expand to meet the growing demand for Life Sciences product-based solutions in North America. PHARMA The company now welcomes Paul Valerio as Operations Manager of the Telstar North America site in B r i s t o l, Pennsylvania. Paul earned his Bachelor of Science and Master of Science in Mechanical Engineering from Lehigh University in Bethlehem, Pennsylvania. He has been involved in many aspects of the design and operation of process equipment throughout his career in the petrochemical and pharmaceutical industries. He began his career performing equipment analysis and design on pressure vessels and processing equipment at Rohm and Haas Company, a specialty chemical company based in Philadelphia, Pennsylvania. Later, he supported the start up of a joint venture acrylic facility in Rho, Italy as an equipment specialist and then returned to USA to lead the maintenance department of a multi-reactor emulsions facility. At Merck and Bristol-Myers Squibb, Paul managed the design of process equipment for parenteral and oral solid dosage facilities, including large scale freeze dryers with automatic loading, specialized cryogenic processes, contained powder transfer, and process integrated isolator systems. He also ran studies to develop new freeze drying cycles for vaccines. Hearing about the capabilities of Telstar and the expanding presence in North America intrigued me., Paul says. I quickly learned that Telstar is a well established company with a unique portfolio of equipment and an energetic and competent workforce. I'm thrilled to be part of the team. Working as Operations Manager is a great opportunity to combine my passion for state of the art equipment and technical excellence with an intense effort to create a world class facility with a strong customer focus. As a customer, I judged equipment suppliers on their ability to cost effectively support all facets of the relationship sales, design, project management, quality, and service. Now I'll focus on pleasing other clients in these critical areas as Telstar grows in North America. Dr. Paul Stewart, President and CEO of Telstar North America, explains, Paul's background in a number of technical, operational, and project management roles in the petro-chemical and pharmaceutical industries brings valuable knowledge to our business. His international experience adds the level of understanding required for working within Telstar worldwide as well as with our diverse customer base. Clients have one more reason to be confident that Telstar is committed to the North American market and that we understand their needs. LIFE SCIENCE SOLUTIONS - Laboratory High containment biological safety cabinets Telstar has broadened its offering of Biological Safety Cabinets (BSC) with a range of high containment equipment including Class III models and isolators. Thanks to these latest additions, Telstar now offers to the market a wide range of Biological Safety Cabinets of classes I, II and III and Pharmacy Isolators. The new cabinets are the result of the experience and reputation of the recently acquired Clean Air Techniek B.V., from The Netherlands, wellrenowned for the manufacture of high-level biocontainment equipment for the northern European market. The applications, operating criteria and specifications of the new BSCs and Isolators from Telstar have been defined by considering the requirements of the leading centres handling bioactive substances. The barriers used to eliminate or minimize exposure to biological materials are called Primary Safety Barriers. Within this category are the class I, II and III biological safety cabinets, isolators, protective suits, breathing apparatus, masks, safety goggles, etc. The Class III Biological Safety Cabinets have been especially designed for the handling of microbiological agents classified as Biosafety level 4 (BSL-4), offering maximum protection to both the environment and the user. These cabinets provide a total sealed, air-tight working area which keep the user completely separated from the product by a physical barrier, with the sample being handled using gloves attached through the sealed window of the cabinet. A HEPA-14 filter located in the rear part of the cabinet continuously supplies filtered air to the working chamber and the evacuated air is passed through another HEPA-14 filter, preventing the release of microorganisms into the environment. Materials are placed inside the cabinet using a pass-through box with a double sealed door, which can be decontaminated between uses. The positive-pressure isolators provide laminar flow in the working chamber, making them ideal for products which have no biological risk but require high sterile conditions. The Isolator main chamber pressure is positive to the room. The main chamber is slightly higher pressure than the passthrough box to maintain aseptic conditions in the main chamber. This equipment not only provides a high level of containment against external contamination, but avoids the risk of cross contamination as they provide laminar air flow to the working chamber. The negative-pressure isolators also provide laminar airflow within the working chamber and are used for products biologically hazardous that also required minimized cross contamination. The barrier isolator pass-through box and main chamber pressure are negative to the room. An additional third HEPA-14 prefiltration stage right below the workbench adapts the isolator to the requirements in the manipulation of hazardous substances like the preparation of cytotoxic medicines as prescribed in some countries recommendations. Sterilator. The new Range of Telstar Clean Air Equipment: MSCIII is a Class III biological Safety Cabinet for handling of microbiological agents classified as Biosafety level 4 (BSL-4). Sterilator is a positive pressure Pharmacy Isolator designed for Aseptic Compounding of Non-Hazardous Pharmaceuticals Cytolator is a negative pressure Pharmacy Isolator designed for Aseptic Compounding of Hazardous Chemotherapy and other Agents that can be Harmful to Pharmacy Personnel providing personnel and product protection.

4 LIFE SCIENCE SOLUTIONS - Hospitals Telstar promotes Vertical Laminar Flow technology for the prevention of infection in the operating theatres Through technical sessions in different forums linked to the medical and hospital sector in Spain, Telstar continues in its efforts to increase awareness of the various vertical laminar flow solutions that are available and the status of projects in progress. As a company specialising in disease prevention, especially in the operating theatre, Telstar advises health technicians about technologies and equipment that can minimize the risk of postoperative infections and which contribute to the safety and prevention criteria recommended by the various current European standards. One of the principal causes of post-operative infection that commonly occurs following surgical interventions in hospitals is contamination by bacteria or viral particles within the operating area. According to a study by the Dutch government (Dutch Health Council TNO report 99 BBI- R014), it is estimated that the costs associated with post-operative infections may represent additional expenses of around 3,600 per patient due to the need to extend their stay in the hospital and to administer additional antibiotics. Following the guidance of the European Working Group (WG 13) regarding ventilation and airconditioning - for which the publication of a unifying European standard is planned for Telstar actively participates in the state working group led by AENOR, the body responsible for normalization and certification in Spain. The goal of these professionals, specialising in topics related to environmental quality in hospitals, is to establish general guidelines on the control of hospital ventilation and to address the way in which air is treated at the most critical points of a hospital, such as ICUs, operating theatres and cytostatic preparation rooms. Telstar's interest in developing technologies to prevent infections in the hospital sector will continue with its future participation in the European Working Group, which includes experts from different countries of the European Telstar operational theatre at the Mútua de Terrassa. community considered leaders in ventilation legislation, such as Germany, Austria and Switzerland. The company will form part of the Spanish representation within this body. LIFE SCIENCE SOLUTIONS - Pharma New Telstar sterilization facility for BD in Mexico Telstar has supplied and installed a complete sterilization facility for BD in Mexico. 3 The whole project included three 72 m ETO sterilization chambers for processing of syringes in palletized cardboard boxes. In addition to zones for pre-conditioning and aeration, the installation also includes a completely automatic loading and unloading system. The scope of supply included: ancilliary equipment, such as ETO gas dispensing system, a clean steam generator, an integrated production parametrical release device and a series of ETO concentration sensors for detection of potential leaks in the working area. All these equipment elements are controlled by a centralized Supervision, Control And Data Acquisition system (SCADA). The entire project has been designed and developed using the latest technology and in accordance with the most up-to-date regulations such that the process strictly fulfills the ATEX regulation for working in explosive atmospheres, and the SIL 2 regulation for personnel protection. Telstar has been supplying ETO sterilizers to BD since 1992, at all times in keeping with worldwide safety regulations. As safety standards are raised worldwide, it was recognised that additional requirements for these units might be necessary. Former design and operation criteria were submitted to an exhaustive functional review in this project. Three different types of studies were carried out: Hierarchy of Risks, Risks Analysis (HAZOP) and Failure Mode and Effect Analysis (FMEA). A safety PLC was integrated for orchestrating control of the entire installation in accordance to regulations required to comply with the SIL 2 classification. Moreover, three important elements of the mechanical construction of the sterilizers were redesigned, namely: the air circulation fan; the jacket, and; the locking system for the doors. Firstly, an external high volume centrifugal fan has been installed on top instead of several magnetically coupled fans. This fan takes the air from the lower portion of one end of the chamber, and transfers it to the upper portion at the other end, via large diameter tubes. As a result, functional efficiency has been improved and the use of magnetic joint connections (which are very complex and expensive) has been avoided, leading also to a reduction of costs associated with maintenance. Tests carried out at factory demonstrated a maximum temperature difference of 0.4 C across the 60 probes installed in the 72m³ chamber, during thermal mapping. Moreover due to the saving of the useful space, the chamber dimensions are smaller for the same loading capacity. Secondly, the new design with discontinuous jacket, made of carbon steel, is preferable from the point of view of economics and due to the air recirculation system; the efficiency of the heating system was also improved. Finally, the automatic locking system for the doors was based on a mechanism of rotary eccentric cams driven by electric motors. This new design improves the efficiency and the safety while at the same time reducing costs. Thanks to this new sterilization facility, BD will improve the efficiency of its cycles, achieve compliance with current emission regulations and enjoy reduced costs, while at the same time ensuring the safety of its workforce. General view of SteriOx for BD in México.

5 VACUUM SOLUTIONS Telstar leak test station for EADS Last December the consortium EADS (European Aeronautic Defence and Space Company) which includes the company Airbus, acquired for its division of Defence and Security a Telstar leak test station for the leak-tightness control of some of the electronic components of the Eurofighter aircraft. Eurofighter is considered the state of the art in multifunctional war aircraft. The equipment supplied by Telstar has been designed to test the cooling circuit of some of the antennas that the Eurofighter uses for its positioning; this requires a high level of confidence and precision. The solution supplied was developed entirely to customer specification; providing a machine fully customized to the characteristics required for the components of EADS. This customized solution offers the possibility to carry out an extensive range of operations, including tests of mechanical resistance, high pressure, leak detection in vacuum chambers and with sniffer and spray, as well as the measurement of the volumetric flow in the part. EADS asked Telstar to include in the delivery a laminar flow bench to supply a clear air for parts handling. EADS is the most important European industrial corporation in the Aerospace and aviation sector. Radar system leak detection equipment. Eurofighter. Intraoperative radiotherapy equipment based on a 12 mev race-track microtron Telstar is taking part in a project to develop a piece of Intraoperative Radiotherapy (IORT) equipment based on a Race-Track electron Microtron (RTM). The main part of the RTM is located within a vacuum chamber that forms the head of the equipment and this head is moved into position using a robotic arm. Specifically, Telstar is responsible for carrying out the process engineering and detailing, for drawing up the technical specifications and for manufacture of the vacuum chamber. The electron beam dynamics have been simulated using RTMTRACE code. For the 2D design of the magnetic system, POISSON code has been used, with the definitive design of the 3D magnets being carried out using ANSYS software. Based on the calculations and the simulation of the movement of the electrons in the RTM, a magnetic system structure consisting of 4 poles has been chosen, and its dimensions and the characteristics of its materials have been defined. Intraoperative Radiotherapy (IORT) using electrons is a treatment method that aims to combine the work of two disciplines, surgery and radiotherapy, in order to improve local tumour control rates. It consists in the administration, directly into the surgical site, of a high dose of radiation within a certain tumour volume delimited by the radiotherapist during the course of a surgical procedure. This makes it possible to reduce errors in the estimation of the treatment volume, as well as protecting the anatomical structures of the normal tissue by segregating or protecting them. The main advantages of the race-track microtron proposed by the project over existing equipment dedicated to intraoperative radiotherapy are that, with the same output beam energy, the weight and dimensions of the race-track microtron are reduced and the power consumption is several times lower than that of the linac. The energy of the output beam electrons is determined, with high precision, by the magnetic field of the magnets used to bend the beam, meaning that it is necessary to calibrate the beam each day. As such, the dose of radiation administered in the operating theatre can be reduced and the number of operations permitted per year can be increased. Cyclotron working principle The output beam energy exchange principle is very simple (extraction from another orbit) for which reason the transverse dimensions of the beam and its energy spectrum do not change. Furthermore, no uncontrolled currents, known as "dark currents", are generated. The project, in which Telstar is participating, involves collaboration between a group of companies, research centres and hospitals, led and managed by the Universitat Politècnica de Catalunya (UPC), and carried out at the Institute of Energy Technologies (INTE) at UPC.

6 EXHIBITIONS AND CONFERENCES Poznan Przemysl Farmacetyczny 2008 Nuremberg Chillventa 2008 Moscow Pharmatech 2008 Dusseldorf Medica 2008 San Diego Pep Talk Conference 2009 Mexico DF Biofarmacéutica 2008 Paris Emballage 2008 Barcelona Ingeniería Hospitalaria 2008 Expoquimia 2008 New York ISPE Barcelona 2008 Interphex NYC 2009 Tampa ISPE Tampa 2009 San Juan Interphex Puerto Rico 2009 Dubai ArabLab 2009 Biofarmaceutica 2008: 8-10 October, Mexico DF (Mexico) Chillventa 2008: October, Nuremberg (Germany) Ingeniería Hospitalaria 2008: October, Barcelona (Spain) Expoquimia 2008: October, Barcelona (Spain) Przemysl Farmacetyczny 2008: November, Poznan (Poland) Emballage 2008: November, Paris (France) Medica 2008: November, Dusseldorf (Germany) Pharmatech 2008: November, Moscow (Russia) ISPE Barcelona 2008: 1-4 December, Barcelona (Spain) ArabLab 2009: January, Dubai (UAE) Pep Talk Conference 2009: January, San Diego (USA) Interphex Puerto Rico 2009: January, San Juan (Puerto Rico) ISPE Tampa 2009: 2-5 March, Tampa (USA) Interphex NYC 2009: March, New York (USA) Coming Exhibitions April 2009 M T W T F S S ISPE-Casa, North Carolina (USA) Energy Hannover Messe, Hannover (Germany) May 2009 June 2009 M T W T F S S M T W T F S S Achema, Frankfurt (Germany) ISPE Barcelona (Spain) FCE Pharma, Sao Paulo (Brazil) Congreso de Medicina Preventiva, Malaga (Spain) ISPE Washington, Washington (USA) Expoquimia Barcelona, October 2008 Pep Talk Conference San Diego, January 2009 ISPE Barcelona, December 2008 Edited by: TELSTAR TECHNOLOGIES, S.L. Photographs: TELSTAR TECHNOLOGIES, S.L National Book Catalogue Number: B TELSTAR TECHNOLOGIES, S.L. Josep Tapiolas, Terrassa T F [email protected]