The pharmaceutical industry is known for requiring high standards in production and cleanliness. As such, controlling dust particles lingering in the facility should be a prime focus to maintain good standing with regulators and consumers.
This article will explore the basics of dust collection in pharmaceutical plants, mainly where the dust comes from and the dangers it brings. We will also look at what to consider when selecting a dust collection setup for a pharmaceutical facility.
How Dust Forms in the Pharmaceutical Industry
In the pharmaceutical field, dust generally occurs during each step of the production process. Grinding the raw materials into powders or granules is one of the main sources of dust particles. This is followed by the mixing of these ingredients to create the formula, and then forming the pills and tablets for consumption.
Why is it important to control these dust particles? These particles, especially in their raw form, contain high levels of allergens that can be harmful to employees. Additionally, they can also get stuck on vents and machines, degrading them over time or causing potential explosions.
Dust-Related Challenges the Pharmaceutical Industry Deals With
The prevalence of dust particles in pharmaceutical plants poses critical challenges that can affect their overall production and output. Overcoming these obstacles not only improves the safety of the plant but the quality of the products they create.
Employee health
Protecting personnel health and wellness is at the top of the list for pharmaceutical plants. Exposure to dust generated when handling raw or processed ingredients may be harmful due to their high concentrations. While there are exposure limits per material dust, plants need to ensure that these limits are properly maintained.
Cross-contamination
Another concern pharmaceutical plants need to deal with is the cross-contamination of products due to lingering dust from other materials. Manufacturing oral solid dosage or OSD products like pills and capsules requires strict monitoring based on standards set by the FDA, EMA, and MHRA. Contamination may either reduce the OSD’s efficacy or trigger allergens that can worsen a patient’s condition, leading to call-backs affecting profit and brand perception.
Potential Fire Hazard
If not properly cleared and disposed of, dust particles generated during the production of OSDs can gather in certain areas within the plant. If left unchecked, the collated dust particles may be exposed to other ingredients, causing an explosion in the facility, and delaying production and additional repair expenses.
Dust Control in the Pharmaceutical Process
After looking into the challenges that the pharmaceutical sector faces, let’s tackle the various ways how these can be handled. Controlling and mitigating dust propagation within a facility requires a systematic approach, and proper implementation ensures smooth and worry-free production.
The first order of business is implementing an efficient dust collector for pharmaceutical plants to control the dust generated during the production process. Dust extraction systems collect the dust once it enters the facility’s ventilation system using highly calibrated dust collector filters. The harmful dust is then properly disposed of while returning the clean air to the facility, improving air quality in the process.
We recommend setting up dust collectors in critical sections of the production plant, particularly in workshops where high dust generation happens. This guarantees that no leftover dust gets stuck on the machinery or air vents while keeping workers safe from dust exposure.
Second is maintaining the quality of the facility’s cleanrooms. Most if not all pharmaceutical plants have cleanrooms that are critical to maintaining their optimal manufacturing levels per global standards. Constantly keeping these cleanrooms 100% dust-free ensures no contamination happens during production.
Strict compliance with safety standards is third on our recommendations for efficient dust control in pharmaceutical plants. This would include wearing the proper equipment before entering workshops and cleanrooms to practicing routine cleaning after every production cycle. Making sure that your employees follow the guidelines will reduce the risk of dust spreading within the facility.
How to Select the Best Dust Collectors for Pharmaceutical Use
Seeing the importance of a dust collector for pharmaceutical facilities, the next order of business is choosing the right one for the task. There are several factors to consider during the process, each playing a key role in an efficient filtration system.
First, know what type of dust the facility is generating. Different materials produce their type of dust, and not all dust collectors fit the bill. The most recommended filters for pharmaceutical plants are made with cellulose o nonwoven blends, while adding secondary HEPA filters will help catch fine particulates. Also, if the facility generates different types of dust, it would be best to use specific filters per workshop or section for efficient dust collection.
Next, consider the placement of dust collectors within the facility. Setting up the dust collectors close to the dust source ensures the harmful particles won’t spread out of the facility. Additionally, you can also enclose specific workshops or production lines that generate the dust and directly connect them to the dust collector for better filtration.
Then there’s the cleaning and maintenance of the dust collectors and their respective filters to include in the equation. Most top-tier air filtration systems have self-cleaning properties, where compressed air is pulsed on the filters, releasing trapped particles in the process. Constantly keeping the filters unclogged will ensure their efficiency and longer service life.
Tysum Dust Control Solutions for Pharmaceuticals
As a globally renowned dust collector manufacturer, Tysum offers various air filtration setups aimed at improving the conditions of pharmaceutical facilities. Designed, manufactured, and tested by industry experts, our dust control solutions effectively collect the finest of dust particles and maintain clean airflow within the plant. With our products, not only is cross-contamination greatly reduced but also safeguarding the overall health of employees and equipment.
Partnering with Tysum as your preferred source of dust collector for pharmaceutical facilities gives you access to our robust production expertise and wealth of experience in the field. Our expert designers assist in creating a tailored dust collection setup that blends well in any facility at the best costs possible. We also ensure that the air filtration system meets regulations set by local and international bodies, including overload protection, thermal switches, and grounding straps.
In addition, we also offer a comprehensive support service to resolve all concerns after order fulfillment and reduce potential downtime. This includes extra accessories and components upon delivery and one-year warranty coverage for minimal maintenance costs.
Elevating the Pharmaceutical Industry with Reliable Dust Collection
Dust collection is a serious matter for pharmaceutical facilities due to the high levels of dust generated during the production process. Without a proper dust collector for pharmaceutical plants set up, lingering dust particles can contaminate the products and affect the health of personnel, directly affecting the profits and brand reputation.
Thankfully, efficient and reliable air filtration systems are available in the market that can take out the dust and maintain clean air within the plant. Knowing the type of dust generated and setting the dust collectors as close to the source ensures continuous production and lower overhead.
Looking for a custom air filtration system for a pharmaceutical facility? Contact the experts at Tysum today for more information.
