Concentration and Purity for Pharmaceutical Applications Using PolyCera® Hydro UF
- Industry: Pharma
Application Overview:
Precise filtration of fermentation broth is a critical step in pharmaceutical manufacturing, where product purity and yield directly affect efficacy and compliance. This project utilized PolyCera® Hydro ultrafiltration (UF) membranes in a pharmaceutical production line to enhance concentration performance while ensuring stable and clean operation. The system, commissioned with a capacity of 600 m³/day, was designed to handle fermentation broth containing proteins, polysaccharides, and suspended solids at a low pH (~3) and within a temperature range of 5 to 45 °C.
Process Design:
The system was configured for batch-mode operation with tight control over concentration levels and cleaning intervals. The filtration process includes:
Fermentation Broth Feed:
Fermentation broth containing a complex mix of organic components, solids, and nutrients enters the system.
PolyCera® Hydro UF Membrane Filtration:
- Retains and concentrates target components.
- Removes impurities while maintaining high flux and low fouling.
Batch Concentration Control:
- System runs in cycles to achieve the desired concentration.
- Cleaning is scheduled between batches to maintain long-term flux stability.
Cleaning Protocols:
Routine backwashing combined with periodic chemical cleaning restores membrane performance and prolongs service life.
Results:
The operation of the PolyCera® Hydro UF system delivered the following results:
- High Concentration Factor: Achieved >25x concentration of fermentation broth, exceeding target specifications.
- Consistent Membrane Performance: Chemical cleaning effectively restored flux after prolonged use, enabling sustained throughput.
- Stable Operation: The system met operational and regulatory requirements for pharmaceutical production with minimal downtime.
Conclusion:
The implementation of PolyCera® Hydro UF membranes in this pharmaceutical setting demonstrates their capability in precision filtration of complex fermentation broths. The system provided high concentration performance, stable operation, and reliable cleanability, supporting both product quality and operational efficiency.
This project confirms PolyCera®’s suitability for high-value process filtration applications in regulated industries such as pharmaceuticals.
