Authored article by Mr Deepesh Upadhyay, AVP, Delair | 26 Sep 2024,
Q: What role does compressed air play in pharmaceutical manufacturing and how does Delair’s desiccant dryer work to remove moisture from compressed air?
Deepesh Upadhyay: Compressed air is an essential requirement of the pharmaceutical industry and finds application in a wide range of processes. It plays a critical role at every stage of manufacturing, right from mixing the powder or producing granules at the time of tablet pressing to giving the right texture, colour, and flavour to the medicines. It is also required at the time of coating and encapsulation, oxidation process, cleaning bottles and containers, and conducting aseptic packaging. In liquid medicines, it ensures accuracy in the balance of the ingredients and maintains precise measurement of each formula.
Therefore, the role of compressed air is very important for the manufacturing of pharmaceutical products, and the presence of moisture in the pressurized air can give rise to quality issues in the medicine. Reducing the effectiveness of drugs, it can result in the revocation of entire batches of medicines from the market and incur huge loss to the company. In order to address the problem, Delair’s desiccant dryer comes with the proficiency to eliminate moisture, dust particles, oil, and other solid contaminants from the compressed air. It conforms to quality standards of ISO 8573-1:2010 Class 1, and maintains the optimal atmospheric dew point temperature range of (-40°C) to (-70°C) max. and work on the principle of heatless regeneration with the help of desiccant to adsorb and desorb water vapour. At the same time, the dryers also make use of pressure swing/ purge air principle to initiate the regeneration of desiccant bed.
Q: Why is the control of moisture particularly critical in the production of hygroscopic pharmaceutical products and how does Delair’s solutions handle this?
Deepesh Upadhyay: As stated above, moisture in compressed air can severely meddle with the tablet manufacturing process. Here, it is important to understand that the various materials used in medicine are hygroscopic in nature. On account of this, at the time of tablet compression, the presence of moisture in compressed air can cause caking and lumping of powdered materials. This can severely impact the entire tableting process and even account for the decomposition of drugs. Overall, compressed air laden with moisture upon coming into contact with the drugs can compromise their medicinal value.
Moving ahead, the destructive effect of moisture can even be seen during the spray coating of the tablets. In the process, moisture comes with the ability to change the colour, smell, and taste of the medicines. It is also responsible for giving rise to blisters on the tablets and, at times, can also lead to the breakage of the tablets as well. Performing uneven coating, inferior-quality tablets are manufactured as end products. All the factors together tend to trigger enzymatic, microbiological and biochemical deterioration of pharmaceutical products.
Here, the Delair products come in handy for efficiently removing the moisture from the compressed air. Consequently, it also contributes to the efficacy of the entire manufacturing process and, in turn, is responsible for the production of high-quality medicines. Conducting all the pneumatic processes under high pressure in a completely dry state aids in passing the quality checks by meeting the highest industry standards.
Q: Explain the role of pneumatic control systems in pharmaceutical manufacturing processes and how does Delair’s technology help in reducing maintenance costs for pneumatic machines and tools?
Deepesh Upadhyay: Pneumatic control systems are very crucial for pharmaceutical manufacturing as they take care of precise, reliable, and safe operation of the various equipment and systems. They come in handy for regulating the process by exercising control over the flow of liquids, gases, and powders to retain the quality and consistency of the products. Additionally, the automated capabilities help in ensuring accuracy and consistency of quantities throughout the dosing, filling, and packaging processes. It is also sought for maintaining the sterility of various operations that prevent contamination of the products.
However, the perils of moisture in compressed air extend even to pneumatic tools and machines, accounting for their malfunctioning. Moisture inherently causes corrosion in pipes, pneumatic operated cylinders, zig & fixtures, and other components. Likewise, it also gives rise to the sluggish and inconsistent functioning of pneumatic valves and cylinders. The problem is further exacerbated during the cold weather when freezing issues become common in the equipment. Having a damaging effect, ultimately, moisture can incur high maintenance costs for the company.
As Delair systems ensure the purity & dryness of compressed air that is devoid of any form of moisture or contaminants, this helps in avoiding any instances of damage to the pneumatic systems. They resist the corrosion of systems and also maintain the optimal performance of the systems.
Q: How does Delair’s compressed air technology align with GMP (Good Manufacturing Practice) standards?
Deepesh Upadhyay: Adhering to the quality standards of ISO 8573-1:2010 Class 1, Delair plays a vital role in supporting GMP practices mandated by government regulations. These guidelines aim to preserve the authenticity and excellence of the pharmaceutical industry by ensuring the production of safe, effective, and high-quality drugs. Delair’s compressed air dryers, utilizing desiccant-based drying technology, treat compressed air to achieve dew point temperatures ranging from -40°C to as low as -70°C. Air dried to a dew point of -70°C is considered 100% dry and meets the highest standards for use in healthcare settings, including as breathable air in hospitals. This technology supports strict hygiene standards in compliance with FDA recommendations, ensuring the quality and safety of pharmaceutical production
Q: What innovations has Delair introduced to improve the efficiency and reliability of compressed air systems in the pharmaceutical industry?
Deepesh Upadhyay: Delair is at the forefront of integrating advanced technologies to enhance the efficiency and reliability of compressed air systems. By seamlessly incorporating digitization and automation, Delair supports state-of-the-art pharmaceutical manufacturing. Its advanced systems enable precise management of energy-saving drying cycles, leveraging the Dew Point Based Dependence System (DPDS) for purge optimization. This technology minimizes purge losses by extending regeneration cycle times, contributing to significant energy savings. Delair’s systems also feature advanced filtration with automatic condensate management and differential pressure gauges, ensuring smooth operation. These systems efficiently remove dust, oil aerosols, and vapors, maintaining high air purity and reliability.
