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Pharmaceutical Turnkey Project: Why Process-driven Solutions Provider is the Key to Success?

Pharmaceutical Turnkey solutions have now become an integral part of the Pharmaceutical processing industry. Now Pharmaceutical and significant chemical-based companies opt for much lesser in-house engineering and project management resources than earlier. Now, the focus is more on API characteristics that have become more relevant than ever.

What are the benefits of a turnkey pharmaceutical project?

The most important reason companies choose the Pharma turnkey projects approach is that it simplifies the development and installation. Pharmaceutical Turnkey solutions provide a complete end-to-end solution to everything – from handling and transporting bulk raw material to dosing, controlled and monitored milling, weighing, or additional milling or powder handling.

With a Pharma turnkey solutions provider by your side, as a customer, you don’t need to

be concerned about coordination and compatibility between multiple suppliers.

Though it seems very simple, these four factors are critical:

Safety of Material :

The protective measures needed for the OEB level affect the design and execution of the installation. The toxicity of many active ingredients means the process must be perfect for containment at a specific OEB level to keep workers safe. An excellent example is cytotoxic products for cancer therapy.

Least ignition energy: 

Some products usually have low ignition levels that require added anti-explosion measures: ATEX execution, Nitrogen inerting and managing Oxygen level, and ATEX execution, to name a few. The NEC or ATEX class requirements play a crucial role in the execution of the installation.

Physical product characteristics: 

The optimal milling process is determined by humidity, susceptibility to oxidation, friability, hardness, softness, elasticity, bulk density, and the product’s temperature sensitivity. It also impacts the upstream and downstream design.

Level of Automation: 

The customer’s need for automation and the management requirements of the previously mentioned risk factors will likely significantly impact the conception and design of the turnkey installation.

Installation requirements of pharma turnkey projects are unique. Therefore, it’s vital to choose a process-driven engineering company with a team of experts with broad experience and knowledge of material science and bulk solid handling experience. According to Roy Housh of Frewitt, the expert milling company, the risk and complexity of these four factors can vary

infinitely.

The demand for Frewitt’s completely engineered solutions is growing yearly, with customers valuing the company’s in-depth process knowledge and experience above all else. “There is a good chance that Frewitt has already processed the same or other material with similar physical

properties and risks. This allows for a faster, more comprehensive, and adapted proposal, most likely with fewer engineering hours, hence far fewer costs,” explains Housh.

In addition, Frewitt’s state-of-the-art laboratories and the staff of material scientists based in Switzerland can quickly confirm that a the process is ideal before elaborating on the concept of any installation design. On the other hand, third-party engineering firms must have laboratories and material scientists to choose and validate an optimal process. 

From individual modules to completely engineered solutions

The company offers proven technology for material handling to ensure a controlled conveyance of products from any bulk container. In addition, high-precision dosing devices, controlled

filtering, inline product sampling, bagging stations, and weighing scales are some of the key modules that complement Frewitt’s renowned milling and crushing technology. Standard and customized WIP, CIP, and SIP designs are compatible with the company’s equipment. Meanwhile, all Frewitt components are controlled by Frewitt’s HMI/PLC.

Delivering results Consistently

With the implementation of each pharmaceutical turnkey project, Frewitt is delivering accurate results for customers. “The responses have been very satisfying,” says Housh, who lists reduced equipment costs, significantly reduced engineering costs, more manageable project management, faster delivery times, smooth and fast start-ups, and short validation times amongst the positive feedback from customers.

Looking to the future, he concludes: “Along with milling and sieving machines, we expect customised engineering solutions to become another pillar of our annual business. Process expertise and engineering expertise are synonymous with customer satisfaction.”

AHU Design in Pharma Industry

What is AHU?

An air handler or air handling unit (often abbreviated to AHU), is used to condition and circulate air as part of a heating, ventilating, and air conditioning system. An air handler is usually a large metal box containing a blower, heating or cooling elements filter racks or chambers, sound attenuators, and dampers. Air handlers usually connect to an HVAC system that distributes the conditioned air through the building and returns it to the AHU. Sometimes AHUs discharge (supply) and admit (return) air directly to and from the space served without ductwork.

Small air handlers, for local use, are called terminal units and may only include an air filter, coil, and blower; these simple terminal units are called blower coils or fan coil units. A larger air handler that conditions 100% outside air, and no recirculated air, is known as a makeup air unit (MAU). An air handler designed for outdoor use, typically on roofs, is a packaged unit (PU) or rooftop unit (RTU).

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