JNTUH College of Engineering Hyderabad

(Autonomous)
Department of Chemical Engineering
IV/IV Year B.Tech. I Semester
TOPIC: EQUIPMENTS AND TECHNIQUES IN PHARMA INDUSTRY

A Minor Project under the guidance of

Dr. T. Bala Narsaiah Ms. Sowmya, Asst. Professor

Professor and Head of Mr. Dipankar Das, Asst. Professor
Department of Chemical Engineering Dr. Ramesh, Asst. Professor
JNTUHCEH, Hyderabad Department of Chemical Engineering
JNTUHCEH, Hyderabad
Presented by
INJETI SUMAHITHA (20011A0815)
KUNTALA SANJANA (20011A0823)
PEROLLA SAI SHRUTHI (20011A0833)
PODILA PAVAN KUMAR (20011A0834)
 EQUIPMENTS &
TECHNIQUES
IN PHARMA INDUSTRY
CONTENTS
Introduction

Plant Process

Different Equipments

Utilities

Zero Liquid Discharge (ZLD)

Future Scope

Conclusion
INTRODUCTION This presentation contains brief
theory about the various unit
Operations, processes and
equipment’s being used in the API
development. It also provides the
selection criteria of various unit
operations, processes like, reaction,
filtration, drying, size reduction,
distillation column, crystallization,
extraction, etc. during the API
development.
The pharmaceutical companies are
adopting product differentiation as a
marketing tool.
The purpose of this study is to
examine the awareness of pharma
industries and also different
techniques used in the industry.
 PLANT PROCESS
 Ware House
 Production
 Quality Control (QC)
 Quality Assurance (QA)
 Research and Development
 Engineering and Projects
 Environment, Health and Safety
(EHS)
 Human Resource and
Administration
 PLANT PROCESS
Ware House:
• Receiving Raw Materials and Packing Materials from
Approved Vendor.
• Dispensing of Raw Material.
• Sending Raw Materials, Packing Materials, and Finished
Goods to Quality Control for Analysis.
• Storage of Raw Materials, Packing Materials, and Finished
Goods for Quarantine (Approved/Rejected).
 PLANT PROCESS
Production:
• Receiving of raw materials and packing materials as per
requirement from Ware House.
• Sending in process and intermediate sample for Analysis to
Quality Control.
Quality Control:
• Sampling and Analysis of Raw Materials, Packing Materials,
Finished Goods and Solvents (Fresh/Recovery).
• Analytical Data Record.
Quality Assurance:
• Control of Documents from All the Departments.
• Issuance and Retrieval of Documents and Quality.
 PLANT PROCESS
Research and Development:
• Design of Lab Scale Experiment (new molecules).
• Yield and Analytical Data Providing for new Molecules Developed.
Engineering and Projects:
• Maintenance and Preventive Maintenance of Equipment’s and
Utilities.
• Qualifications for Equipment’s and Utility System.
Environment, Health, and Safety (EHS):
• Ensuring the Safety of Personnel Environment and Product.
• Maintaining the Safe Working Environment.
• Effluent Treatment Process (ZLD).
• Performing Fire Drills, Mock Drills, and EHS Trainings.
 PLANT PROCESS

Human Resource and Administration:

• Recruiting of candidates Based on Requirement.
• Maintaining of Food and Transport for Employee and any other
Administrative Related Activities.
 DIFFERENT
EQUIPMENTS
 REACTORS

• A typical Batch Reactor consists of a Motor Followed by Gear

Box, Shaft, Shell, Agitator, Jacket, and integral heating/cooling
system. These vessels may vary in size from less than 1 liter to
more than 15,000 liters.
• Motor Capacity, Gear Box Ratio, Type of Agitator, Design
Temperature and Pressure need to be Fixed.
• They are usually fabricated in steel, stainless steel, steel with
glass lined hast alloy.
• Reactor design involves all the basic principles of chemical
engineering with the addition of chemical kinetics.
• Mass transfer, heat transfer and fluid flow are all concerned and
complications arise when, as so often is the case, interaction
occurs between these transfer processes and the reaction itself.
REACTORS
 REACTORS

Reactors are of two types used in Pharma Industry Based on the type of
reactions:
They are : 1) Stainless Steel Reactor 2) Glass Lined Reactor
Stainless Steel Reactor:
• A typical batch reactor consists of a tank with an agitator and integral
heating/cooling system. These vessels may vary in size from less than 1
liter to more than 15,000 liters.
• They are usually fabricated in stainless steel (SS-316, SS-304, SS-316L)
• It is used for basic medium reactions. The main advantage of
stainless-steel reactor is that it has a low instrumental cost and a very
flexible use as it can be stopped fast and easily.
• Overall Heat Transfer Coefficient is more for stainless steel reactor.
 REACTORS

Stainless Steel Glass-lined

REACTORS
 REACTORS

Glass-Lined Reactor:
• Glass-lined steel process equipment is used in virtually all the
world’s pharmaceutical manufacturing facilities.
• It is also widely employed by the chemical, petrochemical,
pesticide, metallurgical and food industries.
• There are several advantages in the unique characteristics of glass
lining that make this material of construction a top selection of
design engineers.
• It is used for acidic medium reactions. It is corrosion resistance,
easy to clean and has many more advantages.
REACTORS
 FILTRATION
• Filtration is any type of various mechanical, physical or biological
operations that separate solids from fluids (liquids or gases) by
adding a medium through which only the fluid can pass.
• The fluid that passes through is called the filtrate.
• Following are the filters commonly used for filtration of
pharmaceutical intermediates and finished APIs.
1) Centrifuge 2) Leaf Filter
3) Sparkler Filter 4) Nutsche Filter
Centrifuge:
• A centrifuge is a device that uses centrifugal force to subject a
specimen to a specified constant force, for example to separate
various components of a fluid.
 FILTRATION

Leaf Filter:
• Leaf filters work by feeding a liquid (dirty influent) into a pressure
vessel under pressure.
• The liquid passes through filter leaves leaving behind the solids in
the form of a cake.
• The Main Principle Involved in Leaf Filter is Surface Filtration.
Sparkler Filter:
• A sparkler type filter is a type of filter that uses a filtering medium
such as activated carbon to remove impurities from a liquid or gas.
• The filter is constructed of a cylindrical vessel that contains a series
of horizontal filter plates with vertical frames called sparklers.
• The principle of sparkler filter operation is based on the principle of
gravity filtration.
 FILTRATION

Centrifuge Sparkler Filter

Leaf Filter
 FILTRATION

Nutsche Filter:
• Nutsche filters can effectively perform the separation of solid
matter from a liquid under pressure or vacuum, in a closed system.
• The ability to isolate the product not only reduces product
handling but also minimizes operator exposure and serves as
environmental protection against solvent vaporization.
 DRYERS

Drying is a mass transfer process consisting of the removal of water or

another solvent by evaporation from a solid, semi-solid or liquid.
Common dryers used in pharmaceutical industry are:
1) Tray dryers 2) Rotary cone vacuum dryers (RCVD)
 DRYERS

Tray dryers:
• A tray dryer in the pharmaceutical industry is used to dry powders,
granules, and other types of materials.
• The drying process is usually done under controlled temperature
and humidity conditions. The principle of a tray dryer is based on
the process of convection drying.
 DRYERS

Rotary cone vacuum dryers (RCVD):

• RCVD consists of a rotating vessel in the shape of a double-cone
supported by two stationary turnnions.
• The vessel is surrounded by a heated jacket and a small vacuum line
is installed within one of the trunnions and extends into the vessel.
 SIZE REDUCTION

Size reduction is a process of reducing large solid unit masses into

small
unit masses, coarse particles, or fine particles. Size reduction process
is also termed as
Comminution or Diminution.
Types of size reduction equipment’s are:
1) Micronizer 2) Sifter/Sieving 3) Multi Miller
Micronizer:
• It is a disintegrator, in which feed particles are entrained in a
pressure jet (steam or air) and whirled through a cylindrical
chamber with sufficient force to break them.
 SIZE REDUCTION

Sifter/Sieving:
• Sifter or screener is an essential part of every pharmaceutical
production process, particularly as product quality and integrity are
so important.
• The use of a sieve gets rid of oversized contamination.
Multi Miller:
• Multi Mill is designed to utilize the principle of variable force swing
beaters having both knife and impact edges rotating within a
selected screen to control the particle reduction.
• The principle involves variable force, rotating blades having both
knife and sharp edges with validated screen size to reduce particles
in a controlled manner.
 SIZE REDUCTION

Micronizer Sieving

Multi Miller
 DISTILLATION COLUMN
• Distillation is a chemical process where a mixture made of two or
more liquids (called "components") with different boiling points can
be separated from each other.
• The mass transfer operation involved in distillation process is
Separation.
• The mixture is heated until one of the component boils. The vapour is
then fed into a condenser, which cools the vapour and changes it
back into a liquid that is called "distillate”, what remains in the
original container is called the "residue".
• Types of Distillation:
1)Atmospheric Distillation
2) Vacuum/ High Vacuum Distillation
3) Fractional Distillation
 DISTILLATION COLUMN

Atmospheric distillation:
• Check the solvent boiling point and thermal stability of product
ensures distillation equipment should contain thermometer to check
the temperature of reaction mass and vapour and uses the silicon oil
for distillation temperature above 150.0°C.
 DISTILLATION COLUMN

Vacuum distillation:
• Establish the optimum vacuum range for distillation to get maximum
recovery and ensures the receiver should have 50.0% free space on
vacuum distillation.
 DISTILLATION COLUMN

Fractional distillation:
• Check the solvent boiling point and thermal stability of product and
selects the column size based on difference in solvent boiling point and
to attain the desired quality. It ensures the receiver should have 25.0%
free space and chilled properly by keeping in ice bath.
 SOLVENT RECOVERY SYSTEM

• A solvent recovery system is a process system that takes effluent

and extracts useful raw materials back out of the process waste
stream.
• They can reduce the demand for raw materials, by recovering
chemicals that can be reused in production, or used to flush the
system between runs.
• The solvent input is 70%-75%.
• It consists of :
1) Kettle Reboiler
2) Distillation Column
3) Condenser
4) Decanter
SOLVENT RECOVERY SYSTEM
UTILITIES
 UTILITIES

Basically, pharma industry uses three types of utilities. They are:

1) Boiler for the Generation of steam Utility.
2) Cooling Tower for the Generation of Room Temperature Water
(RTC)Utility.
3) Chiller for the Generation of brine Utility.
Boiler:
• A boiler is defined as a closed vessel which is used to heat liquid
usually water or to generate vapour or steam or any of such
combination under pressure for external use by combustion of fossil
fuels.
• The basic principle of the boiler is to convert water into steam by
using heat energy.
UTILITIES
 UTILITIES

Cooling Tower:
• A cooling tower is a heat rejection device that rejects waste heat to
the atmosphere through the cooling of a water stream to a lower
temperature.
• Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of closed circuit dry cooling towers, rely
solely on air to cool the working fluid to near the dry-bulb air
temperature.
• The classification is based on the type of air induction into the
tower: the main types of cooling towers are
Natural Draft, Forced Draft and Induced Draft cooling towers.
UTILITIES
UTILITIES
 UTILITIES

Chiller:
• A chiller is a machine that removes heat from a liquid via a vapor-
compression or absorption refrigeration cycle.
• This liquid can then be circulated through a heat exchanger to cool
equipment, or another process stream (such as air or process
water).
• As a necessary by product, refrigeration creates waste heat that
must be exhausted to ambience, or for greater efficiency, recovered
for heating purposes.
• Chilled water is used to cool and dehumidify air in mid- to large-size
commercial, industrial, and institutional facilities.
• Water chillers can be water-cooled, air-cooled, or evaporatively
cooled.
UTILITIES
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE
• Zero liquid discharge (ZLD) is an engineering approach to effluent
treatment where all water is recovered and contaminants are
reduced to solid waste.
• While many effluent treatment processes attempt to maximize the
recovery of freshwater and minimize waste, ZLD is the most
demanding target because the cost and challenges of recovery
increase as the wastewater gets more concentrated.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE
Basically, ZLD has different steps:
 Primary Treatment

 Stripper

 Multiple effect evaporator (MEE)

 Agitated thin film dryer (ATFD)

 Biological Treatment

 Ultra Filtration

 Reverse Osmosis
 ZERO LIQUID DISCHARGE

Primary Treatment:
• In general effluent water consists of both High total dissolved
solids (HTDS) and Low total dissolved solids (LTDS).
• After passing the Effluent water through preliminary treatment,
the HTDS water and LTDS water gets separated, then the HTDS
water arrives at Primary Treatment.
• The HTDS effluent water can Acidic or Basic.
• The Main purpose of primary treatment is to neutralize the HTDS
effluent water i.e. pH neutralization takes place and to check the
TDS value.
• Primary Treatment aims to reduce the Biochemical Oxygen
Demand (BOD) and Total Suspended Solids (TSS) in the
wastewater.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE

Stripper :
• Stripping is a physical separation process where one or more
components are removed from a liquid stream by a vapor stream. In
industrial applications the liquid and vapor streams can have
co-current or counter current flows.
• Stripping is usually carried out in either a packed or tray column.
• The main principle involved in Stripper is Absorption.
• The basic principle of stripping is to reduce the value of chemical
oxygen demand (COD) and also for the separation of solvents and the
HTDS water i.e. from a liquid stream by vapour stream.
• The unit operations involving in stripping are Shell and tube heat
exchanger, Plate heat exchanger.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE

Multiple Effect Evaporator(MEE) :

• Multiple effect evaporator (MEE), involves structured sequencing of
the evaporators, with the number of evaporators or effects
commonly restricted to four, unless another specific design is
required.
• A multiple effect evaporator is an apparatus that efficiently uses the
heat from steam to evaporate water.
• In a multiple effect evaporator, water is boiled in a sequence of
vessels, each of which is at a lower pressure than the last.
• As the boiling point of the water decreases with pressure, the vapor
produced in one vessel can be used to heat the next vessel.
• The main principle involved in MEE is Evaporation.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE

Agitated Thin Film Dryer(ATFD) :

• Agitated thin-film dryer (ATFD) is used for continuous drying of
heat-sensitive products under vacuum with total solvent recovery.
• ATFD provides high throughput by efficiently working under
vacuum.
• ATFD uses indirect heating and drying in inert conditions which is
effective for heat and oxygen sensitive products
• The principle of operation of ATFD is continuous processing of
concentrated materials to dry solids by using intense agitation for
effective heat transfer.
• The heating surface is renewed by continuous scrapping of dry
solids for efficient heat transfer.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE

Biological Treatment :
• Biological wastewater treatment is a modern technique in which
wastewater is treated with microorganisms instead of chemicals.
• The LTDS water present in the blending tank undergoes the
biological treatment.
• In biological wastewater treatment, many aerobic as well as
anaerobic microorganisms can be used in various methods to reduce
different types of pollutants present in water and to reduce
biochemical oxygen demand of water.
• The Biological treatment takes place in a tank where the LTDS water
is mixed with the jaggery and different types of pollutants present in
water are removed.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE

Ultra Filtration(UF) :
• Ultrafiltration (UF) is a water purification process in which water is
forced through a semipermeable membrane.
• Suspended solids and high-molecular-weight solutes remain on one
side of the membrane, the retentive side, while water and low-
molecular-weight solutes filter through the membrane to the
permeate side.
• UF can remove most organic molecules and viruses, as well as a
range of salts.
• It has gained popularity because it produces a stable water quality
no matter the source water, has a compact physical footprint,
removes 90-100% of pathogens, and does not require chemicals,
except for cleaning membranes.
ZERO LIQUID DISCHARGE
 ZERO LIQUID DISCHARGE
Reverse Osmosis :
• Reverse osmosis is a water purification technology in which an applied
pressure is used to overcome osmotic pressure, a colligative property
that is driven by chemical potential, a thermodynamic parameter.
• Reverse osmosis removes many type molecules and ions from
solutions, including bacteria, and is used in both industry and potable-
water production.
• In the process of reverse osmosis, the solute is retained on the
pressurized side of the membrane and the pure solvent passes
through the membrane.
• The membrane “selectively" allows smaller component solutions, such
as the solvent to pass freely, while not allowing large molecules or
ions through the pores.
ZERO LIQUID DISCHARGE
ZERO LIQUID DISCHARGE
 FUTURE
SCOPE
&
CONCLUSION
 FUTURE SCOPE

ZLD
 Zero liquid discharge is one of the leading wastewater treatment
processes with recovery of about 90% to 95% of water from
effluents with no liquid waste.
 The recovered water can be reused for industrial or non-potable
applications or can be safely discharged into the environment.
 Thus, the presence of government mandate and high recovery rate
of the zero liquid discharge process are likely to provide new
opportunities to the India zero liquid discharge market.
 Recovery cost of zero liquid discharge plants is significantly high.
This is expected to adversely affect the India zero liquid discharge
market in the near future. The India zero liquid discharge market is
highly fragmented.
 FUTURE SCOPE
PHARMA INDUSTRY
 The Indian pharmaceutical sector is one of the fastest growing
industries with a lot of potential.
 Pharmacy graduates can work in several different industries such
as sales, marketing, research and development, manufacturing,
quality check, education, etc. Working in the Pharmacy industry is
comparatively stable.
 The pharmaceutical industry is facing huge challenges from ethical
issues to financial ones. By embracing disruptive technology like 3D
printed drugs, artificial intelligence guided therapies and preventive
medicine while working with regulatory agencies to make all this
safe for patients, they can benefit from the digital revolution.
 The scope in the pharmaceutical industry is quality assurance is
undeniable and large.
 CONCLUSION
 As a part of our industry oriented mini project on “Equipments and
Techniques in Pharma Industry” we have experienced and learnt the
concepts of various departments i.e. unit operations, plant process,
utilities, basic concepts of reactors, filtration, distillation, etc.
 The concepts of optimisation, effluent treatment plant (zero liquid
discharge plant) and solvent recovery system made us to know what
is the major role of chemical engineer in pharma industries.
 We have learnt the various principles and operations of mass
transfer and heat transfer and the various departments that plays a
major role in the industry sector.
 Continuous pharmaceutical manufacturing offers potential flexibility,
quality, and economic advantages over batch processing, both in
process development and manufacturing for the pharmaceutical
sector.
 INJETI SUMAHITHA (20011A0815)
KUNTALA SANJANA (20011A0823)
PEROLLA SAI SHRUTHI (20011A0833)
PODILA PAVAN KUMAR (20011A0834)