12/07/2010

Article for Manufacturing Chemist –
Process Engineering Feature
DEPTH FILTRATION FOR PHARMACEUTICALS

It’s some time now since we last looked at how depth filtration techniques are changing to suit the demand for increasingly selective filtration performance by fine chemicals and pharmaceuticals manufacturers. So we decided to find out what’s been happening over the last couple of years. One leading UK manufacturer, Carlson Filtration Limited has just completed an eighteen month development programme that has concentrated on two main areas: 1. Continuing research into the adsorptive properties of different grades of activated carbon is incorporated into the CarlCarb range of depth filter sheets. The carbon constituent removes colour bodies, colour precursors and other impurities from pharmaceuticals intermediates and finished products. 2. Development of filtration application data that can be used to predict the performance of different depth filter sheets in a range of applications. Before looking at these developments in more detail, it is worth reviewing how depth filtration sheets work: • Screening - physical screening or sieving at the depth filter sheet surface removes larger particulate matter. • Entrapment and Absorption – Finer particles are trapped within the depth filter sheet structure. • Adsorbtion – Sub-micron particulate matter and ionic materials are selectively adsorbed by the electro-kinetic properties of the carbon source chosen for each application. As far as selective filtration performance is concerned, in Carlson’s case this has included examination of the adsorptive properties of activated carbons derived from different original base structures and sources, using three tracer impurities, iodine, methylene blue and molasses. These are widely used in the activated carbon industry and characterise the distribution of micro, meso and macro pores, respectively, in turn measuring the adsorption capability for various molecular size contaminants. The results of Carlson’s latest development programme predict the absorption rates and particle size ranges that can be removed by different base carbon structures. In addition to the primary function of impurity removal by adsorption, there are three main customer requirements to bear in mind; obtaining the required purity, achieving maximum flow rates and maximising filter sheet life. The main challenge is to find the optimum between these parameters for individual customers. Using this data, Carlson is able to advise pharmaceutical and chemical manufacturers how to select the most appropriate carbon type and filter sheet size and format for their individual application. DEPTH FILTER SHEET FORMATS In order to cater for the wide variety of depth filtration applications and regimes used in the industry, along with most manufacturers, Carlson offers its sheet range in a host of sizes and formats. The range is available in a variety of individual depth filter sheet sizes to suit different filter presses, ranging from 20cm x 20cm right through to 100cm x 100cm. Alternatively the range is available in CarLent lenticular module format. The CarLent lenticular module format is available in either 12 or 16 inch diameter modules and is ideally suited to filtration of high value products in short runs such as pharmaceuticals and fine chemicals. Along with many manufacturers, Carlson has put a lot of time and effort into the development of these modules to achieve an increased number of filter batch cycles before the module has to be replaced, with resulting lower product losses in the spent module. The latest designs also provide the flexibility to accommodate a far greater range of different filter media; from lighter, thinner types right through to denser, harder grades, thus expanding the range of filtration applications. SKID MOUNTED LENTICULAR FILTER SYSTEM The CarLent lenticular module design can be incorporated into a Skid-Mounted Lenticular Depth Filter System. Designed for convenient, clean and efficient depth filtration, this innovative system is a turnkey solution for most process filtration duties. Carlson Filtration’s Skid Mounted CarLent Lenticular Filter The skid mounted system is supplied complete with filter housings, drip tray, pumps and valves. Traditionally, customers would have to design, source and install all these components and then hard-pipe them into their process. This is now taken in-house. The advanced design of the lenticular housing facilitates easy filter changes with minimal changeover times in the secure enclosed drip tray without the need for an additional bund wall.

24/07/2009

Reaching new depths

Leading UK depth filter equipment and media manufacturer Carlson Filtration has recently launched a number of new depth filtration products and the latest in a series of regular lenticular filter developments is the new CarLent lenticular module design, ideally suited to the filtration of high value products in short runs, especially prior to bottling. The long life of the new module allows an increased number of filter batch cycles before the module has to be replaced, with resulting lower product losses in the spent module. Moreover, the new design incorporates significant advances that equip the new module with a number of important competitive advantages including: • Longer module life through the addition of support and location lugs providing additional support to the module during aggressive sanitation operations. • Easier spent module removal because individual cells within the module are more rigidly held in place during lifting. The new design also provides the flexibility to accommodate a far greater range of different filter media; from lighter, thinner types right through to denser, harder grades, for example those containing activated carbon. Carlson envisages that the ever-increasing variety of future filtration duties will call for development of a much broader media range to cater for precise customer requirements. Carlson’s new lenticular module design can be incorporated into Carlson’s Skid-Mounted Lenticular Depth Filter System. Designed for convenient, clean and efficient depth filtration, Carlson’s system is a turnkey solution for most process filtration duties. Carlson’s skid mounted system is supplied complete with filter housings, drip tray, pumps and valves. Traditionally, customers would have to design, source and install all these components and then hard-pipe them in to their process. Carlson now takes all this in-house. The advanced design of the lenticular housing facilitates easy filter changes with minimal changeover times in the secure enclosed drip tray without the need for an additional bund wall. Carlson has recently launched the CarLent lenticular module lifting system. Designed to lift 16” diameter, spent lenticular modules out of the filter housing, the lifting device is designed to shorten changeover times and negate manual lifting, thus increasing productivity and safety standards. Especially useful for three and four high, 16” module housings, the device employs a method of gripping the modules so they can be lifted out of the housing in a single lift and deposited without having to put the lifting device back down. The spent modules can be safely dropped out or the base of the unit with the simple pull of a handle. Carlson envisages that the ever increasing variety of future filtration duties will call for development of a much broader media range to cater for precise customer requirements. The advanced design of the lenticular housing facilitates easy filter chances with minimal changeover times in the secure enclosed drip tray without the need for an additional bund wall.

24/07/2009

Aseptic Filling & Packaging

Further developments

Leading UK depth filter equipment and media manufacturer Carlson Filtration has recently launched a number of new filtration products that will be of particular interest to beverage packers. Effective sterile beverage filtration is best achieved during the final, pre-packing, stage. For this duty Carlson offers its CarlCart Membrane MP/W 0.45 or 0.65 pleated PES membrane cartridge. The filter medium incorporated into this type of cartridge consists of a highly asymmetric polyethersulphone with upstream and downstream polyester drainage layers. When using this type of filter, it is important to incorporate a pre-sterile filtration step, as the membranes are not designed to take high loading but as a final sterile guard. For this duty Carlson recommends the CarlCart Pleated PL 1.0µm absolute or Glass Fibre GF 0.2µm nominal cartridge. Additional security is sometimes required during manufacturing of some beverages such as beers, lagers and wines, for example where mechanical kieselguhr (KG) support services are used. A trap filter is commonly employed for this duty to avoid carryover of impurities that might affect subsequent clarification or sterilisation steps. To achieve this, Carlson recommends the CarlCart pleated PL 3.0/5.0/10.0/20.0µm trap cartridge system, sized to suit the up-stream filtration load. All CarlCart products are manufactured in strictly controlled environments so that their high quality and purity filter elements meet the requirements of various international guidelines. Carlson’s MP/W sterilising membrane is fully bacterial retentive and is manufactured in a class 10,000 clean room (M4), in accordance with cGMP guidelines. All materials of construction are chemically and biologically inert in accordance with FDA, USP and EEC directives. Based on these specifications, CarlCart cartridge filters offer a number of key benefits including, high flow rates, long service life, very good chemical resistance and consistent high quality.

24/07/2009

CarlCart process and membrane filter cartridges for the brewing industry

Carlson Filtration has supplied the brewing industry with filtration products for over eight decades and its main aim has always been to help the brewer to produce stable, fresh, bright beer. Carlson’s CarlCart range of process and membrane filter cartridges are typically used in a number of stages of the brewing process including: Pleated Cartridge Trap Filtration As additional security, or if other types of mechanical keiselguhr (KG) support services are used, a trap filter is commonly employed to avoid carryover of KG powder that might bleed through the mechanical support surface. To achieve this, Carlson recommends its CarlCart pleated PL 3.0/5.0/10.0/20.0µ trap cartridge system, sized to suit the up-stream KG filter capacity. Membrane Filter Sterilisation Effective cold sterile filtration of beers and lagers is best achieved during a final, pre-packing, stage. For this duty Carlson recommends its CarlCart Membrane MP/W 0.65µ or, more commonly, 0.45µ pleated PES membrane cartridge. The filter medium incorporated into this type of cartridge is a highly asymmetric polyethersulphone with upstream and downstream polyester drainage layers. When using this type of filter, it is important to incorporate a pre-sterile filtration step, as the membranes are not designed to take high loading but as a final sterile guard. For this duty Carlson recommends its CarlCart Pleated PL 1.0µ absolute or Glass Fibre GF 0.2µ nominal cartridge. CarlCart products are manufactured in strictly controlled environments so that their high quality and purity filter elements meet the requirements of various international guidelines. Carlson’s MP/W sterilizing membrane is fully bacterial retentive and is manufactured in a class 10,000 CLEAN ROOM (M4), in accordance with cGMP guidelines. All materials of construction are chemically and biologically inert in accordance with F.D.A., U.S.P and E.E.C. directives. Based on these specifications, CarlCart membrane filters offer a number of key benefits including, high flow rates, long service life, very good chemical resistance and consistent high quality.