Filtration

The principles and practices of lean manufacturing are widely used in industries across the globe to continuously improve processes, drive efficiencies and reduce costs.

Even in biopharmaceutical manufacturing where validation and regulatory requirements are high, lean can be used to improve processes, meaning more life-saving product can reach patients quickly.

Technology has been developed to support biopharmaceutical manufacturers, CMOs and CDMOs on their lean journey and at Parker we have worked closely with industry to develop a system that can improve operational efficiency, accuracy and safety.

 

Parker’s SciLog® FD System automates, standardizes and encloses final bulk filtration and dispense operations. It can support companies in addressing the eight wastes of lean: Transportation, inventory, motion, waiting, overprocessing, overproduction, defects, and safety.

As an automated, standardized and enclosed single-use system, it has many advantages over manual operations. It can increase efficiency, reduce process variation, protect the product and operator, and reduce risk.

Here is how the SciLog® FD System can help manufacturers tackle the eight wastes, and support them in implementing lean production strategies.

 

Transportation

As the process takes place in a single, enclosed system, the movement of products and materials is reduced. The SciLog® FD System can combine two unit operations: the sterile filtration of bulk drug product and its dispense into bottles or bags. As both of these steps can be performed on one system, transport of material is reduced. Once dispensed into bags or bottles, the drug product can be easily transported for freezing or cold storage.

 

Inventory

The use of the SciLog® FD System simplifies the supply chain, with the hardware and consumables, including single-use manifolds, designed together and available from a single source – Parker.

 

Motion

Using an automated system means that the motions associated with a manual operator – for instance operating pumps and valves – are removed from the process. All of the valves are controlled automatically, with intelligent feedback from the SciLog® single-use sensors which are part of the system.

Moving materials in a laminar air flow using aseptic technique can be challenging and has a high training requirement. Reducing the amount of movement of product through the use of a closed system reduces the risk of contaminated product. The SciLog® FD System allows recipe-driven processing, sampling and integrity testing — all taking place on the one enclosed automated system limiting unnecessary motion and associated risk.

 

Waiting

As the SciLog® FD System is automated, it cuts down on an operator’s waiting time in between different stages of the process. This means that staff can be utilized more efficiently. For example, a recipe can be programmed to carry out an automated filter integrity test and, while this takes place, the operator can perform other activities such as checks or paperwork completion.

 

Overprocessing

Time-consuming, and potentially inconstant tasks that would have been carried out manually are now automated. For instance, the SciLog® FD System generates automated batch records - an alternative to the operator having to complete forms manually (and reducing the risk of transcript error). There is also an integrated label printer with labels suited to cryogenic storage. 

 

Overproduction

Manual fill can be inaccurate - and human error can lead to more product being transferred to a bottle than is required. Clearly this can have a significant impact on production and, given the high value of the product, can be financially damaging too. By automating the bulk fill process, costly inaccuracies can be avoided. In the SciLog® FD System, load cells located under receiving containers ensure direct measurement for high dispense accuracy. 

 

Defects

An open process which relies on manual handling can result in contamination of a product and batch loss. Enclosing the process means that the product is protected and the risk of any contamination is greatly reduced. In addition, standardization and automation eliminate process variability and enables batch repeatability. Standardized, reliable programming ensures repeatability and control in the process. 

As calibrated SciPres® single-use pressure sensors are included in the SciLog® FD System, operators can ensure that validated pressure limits are not exceeded, protecting the manifold and controlling the differential pressure over the filter. 

 

Safety

Utilizing a fully enclosed process means the product is protected from contamination by the operator, but crucially also that the operator is protected from potentially highly potent molecules.

There are also additional advantages to using Parker’s SciLog® FD System which supports the application of lean in biopharmaceutical manufacturing. Standardization means that training is made simpler and easier, and by using a single-use system, change over times can be significantly reduced. The installation of manifolds in the system is quick and easy, again reducing labour costs and time spent on manual tasks.

 

To learn more about how the SciLog® FD System can help you tackle the eight wastes of lean, please visit our webpage.  

 

 

This post was contributed by David Heaney, market development manager, Parker Bioscience Filtration, UK

Parker Bioscience Filtration specializes in automating and controlling bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

 

 

 

Related content

Automating and Enclosing Bulk Fill Operations - the Way Forward?

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Four Sources of Process Variation in Biopharmaceutical Manufacturing

 

One the biggest challenges for original equipment manufacturers (OEMs) in automotive manufacturing is ensuring reliable operation and long-term performance of equipment. Liquid and particulate contaminants, pressure build-up, temperature fluctuations and harsh environmental conditions can have devastating effects on sensitive components resulting in costly maintenance, downtime and part failure. What is the best line of defense? Are there new technologies available that provide an effective solution? Let's explore some options.

Components that are especially vulnerable include:

• Automotive lighting an lamp housings
• Electrical motors
• Electronic control units and enclosures
• Battery vents
• Fluid reservoirs

An effective solution - membrane vents

Many OEMs use membrane vents. Membrane vents are designed to equalize pressure and reduce condensation while preventing ingress of liquid and other contaminants to keep automotive components and devices operating properly.
 

Look at the data

When selecting membrane vents, it is important to review the following performance testing data:

• Air Permeability - is a measure of the rate of air flow per unit area through a membrane at a specified pressure. The higher the air permeability, the lower the water entry pressure.
• Wet Mullen Burst - is a type of water entry pressure test that measures a membrane's hydrophobicity. It is the pressure required to force water through the membrane. The higher the recorded pressure, the higher the protection against water entry.
• Oil Repellancy: this test evaluates a membrane's resistance to wetting by a selected series of hydrocarbons of differing surface tensions. The oil repellency grade is the highest numbered test liquid that does not wet the membrane surface. The better the oil repellency grade, the higher the resistance to staining by oily fluids and the better the protection.
   

Intangible benefits

Another important factor to consider when selecting membrane vents is the reputation of the manufacturer and the quality of customer service they provide. Additional attributes to look for include:

• Rapid response times
• On-time delivery guarantees
• Technical service
• Application support
• Engineering expertise

 

New technology

Vents made from expanded polytetrafluoroethylene (ePTFE), such as aspire® membrane laminates, are particularly effective for automotive applications. aspire membrane vents combine high water entry pressure with high air permeability to exceed automotive manufacturing requirements. The membranes are laminated to polymer meshes to provide the physical stability required for integration into automotive components and throughout operation. Proprietary oleophobic chemistry provides the level of ingress protection necessary to ensure long-term performance of automotive equipment.

 

aspire® performance data

 

Conclusion

Choosing the best membrane vent solution for automotive applications takes careful evaluation. Considering services and support the manufacturer provides, performance data and the effectiveness of the technology are key factors to ensure reliable, long-term operation of automotive components.

To learn more about aspire membrane laminates and die cut vents for automotive applications, please visit the website.

 

Article contributed by Sarah Propp, engineering manager, Parker Performance Materials.

 

 

 

 

 

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Computer Numerical Control (CNC) machining is a process where computer-aided design (CAD) and computer-aided manufacturing (CAM) programs are used to control the steps and functions of machine tool centers, allowing repetitive production processes to be programmed and automated. CNC machining and milling centers, as well as CNC lathes, are precision cutting machinery commonly used in industrial manufacturing applications such as metalworking. These centers have several axes, in which tools and workpieces move. Workpiece and tool changers supplement the systems so that complex geometries can be produced on one machine tool.

Today’s high-speed processing requires the introduction of cooling lubricants. These are used to cool the cutting edges on the direct contact surface to the workpiece during the cutting procedure, to lubricate the contact surface and remove any arising chippings through “purging”. Through the rotation and energy input, the cooling lubricant forms an aerosol mist, which is extremely hazardous to health if inhaled.

Let's explore how one metalworking manufacturer solved the problem of CNC machining emulsion mist and improved air quality in its production facility.

 

Problem:

Mauersberger und Fritzsche is an SME with a long tradition in gear manufacturing for drive technology and in the production of high-quality structural steel cupped shears. The company has CNC machining and milling centers from renowned manufacturers, such as Monforts, Doosan, Yang and Mori Seiki, in which workpieces are cooled, purged and lubricated with water-soluble cooling lubricants (emulsions). To improve air quality and safety, the corporate management team turned to Parker Industrial Gas Filtration Generation Division to design a solution to remove the hazardous emulsion mist.

For application details, download the case study "Extraction Of Emulsion Mist From Various CNC Machine Tools Using Central Extraction".

 

 

 

Solution:

The company’s machinery comprises approximately 10 machine tools. For this reason, the advantages and disadvantages of single-station extraction units were weighed against a central extraction system.

The advantages of a central extraction system prevailed in this project. On balance, the investment costs are lower despite higher costs for piping and assembly, while maintenance is concentrated on a central point. In addition, a summer/winter set-up as hall ventilation can be easily realized with this concept. This allows exhaust air operation in the summer and a recirculated air operation in the winter to save heating costs.

In general, it is not possible to give one blanket answer to the question about single-station extraction units or central extraction systems. This must be decided on the facts of the relevant plant. However, as a general rule, the overall or life cycle costs of a central system with a ventilation system performance from 6,000m³/h tend to be lower. In this case, Parker recommended a SmogHog ESP two-staged electrostatic filter which reliably filters out harmful substances and emulsion mist, such as aerosols, and offers the client an approximately 15% reserve for production expansions.

The client was initially skeptical about an electrostatic filter solution. However, thousands of installed SmogHog electrostatic filter systems have proven successful for decades. Even oil and emulsion mists can be filtered with outstanding results if you have 50 years of knowledge like Parker. Knowledge, which can also be seen, for example, in the piping used for raw (polluted) gas, as this should be made of longitudinally welded steel and be oil-tight on the flange connections. “Cheaper” folded spiral-seam pipes are reputed to save costs but, according to Parker's experience, they carry a risk of a production hall becoming a “stalactite cave”. By visiting a comparable reference system near the client’s company, Parker was able to convincingly prove this knowledge, dissipate the reservations and win the trust of the user. This and independent measurements by the Institut für Luftund Kältetechnik convinced the client to award the contract to Parker. 
 

Advantages of the Parker ESP system

• Higher filtration efficiency of oil and emulsion aerosols - even for the smallest particles (< 1µm).
• Lower energy consumption due to the low pressure losses of the filter system - almost independent of the contaminant loads and load capacity of the filter elements.
• No disposable parts and, consequently no need to dispose of the filtering media (hazardous waste).
• Equipment design is tailored by Parker Hannifin to the user’s needs.
• Equipment in use for at least 10 years (up to 25 years with Parker Hannifin service).

Key technical data

• Product SH 60/T with two electrostatic stages in series
• Suction output under operating conditions: 12,000m³/h
• Power consumption of ventilator: 7.5kW
• Power supply: 400V/50Hz • Filter weight: approx. 900kg
• Filter surface: 156m² electrostatic
• Pressure loss of filter: 1.5mbar (150Pa)
• Paint RAL 7035 • Max. process temperature: 65°C
  
   

Results

The client is very satisfied with the performance and maintenance intervals of the system, especially as they clean the filter elements on-site and reuse the filter inserts.

Watch this video to learn more about Smoghog:

 

For additional information, download the case study "Extraction Of Emulsion Mist From Various CNC Machine Tools Using Central Extraction".

 

This article was contributed by the Filtration Team.

Thanks to Dr. Truschka and the company for approving this article and the pictures. Authors: Carlo Saling, Norbert Jedrzejak and Jörn Jacobs

 

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Do you need to detect ferrous wear particles in machinery? Are you working remotely, onboard a vessel, or onsite in a less than ideal environment? Ferrous wear meters allow users to measure ferrous wear debris in oil samples for condition monitoring in both marine engines and lubricated machinery.

 

Detecting metal particles

The Parker Ferrous Wear Meter (FWM) is a simple, easy-to-use instrument that provides accurate, reliable detection of metal particles in oil samples taken from a variety of types of machinery, including used cylinder scrape down oil, gearboxes and bearings. Monitoring of ferrous wear levels with your oil samples on an ongoing basis allows any deterioration in machine condition to be quickly spotted and corrective action taken, saving you downtime and money, and preventing more serious damage occurring. This versatile unit is ideal for testing and analysing oil samples on-site, on-board or in remote locations where full laboratory analysis is not possible.

Features include: 

• Suitable for testing on-board, on-site or in remote locations.
• Simple, easy to operate instrument requiring minimal training.
• Direct reading in PPM on the LCD screen. 

 

The FWM is constructed using a sophisticated magnetometer adapted for field applications. A 5-millilitre test tube, filled with the sample, is placed directly in the hole in the instrument and its metallic content, in PPM, is displayed on the screen in less than 2 seconds. 

By taking ferrous wear measurements over time, any increase in wear levels can be monitored and appropriate actions taken to mitigate any damage. Machinery degradation can be observed as it happens and machines serviced as and when they need to be, rather than on a time or hours of operation basis, saving costs and manpower.

 

    Performing a ferrous wear test

 

Each ferrous wear meter is supplied with three check standards to verify the product on a regular basis. In this example, 
the 972 - 922 PPM ferrous content sample is being used. 

 

 

 

 

Step 1

As per the on-screen instructions, insert the sample into the FWM for approximately one second, then remove. The result will be displayed on the screen for comparison against the check standard.

 

 

 

 

Step 2

Begin by agitating your oil sample for approximately 30 seconds. Fill a 5-millilitre test tube to within 5-millimetres of the top with your oil sample. For each test, use a new test tube.

 

 

 

 

Step 3 Insert the oil sample into the ferrous wear meter for approximately 1 second. Then remove. 

 

 

 

 

 

Step 4

The results will display shortly after removal.

 

 

 

 

 

 

Watch this step by step video for complete instructions:

 

 

 

To learn more about the Parker Ferrous Wear Meter, download our datasheet.

 

 

 

 

 

 

 

Please visit our Hydraulic and Industrial Process Filtration Division EMEA for additional information.

 

This post was contributed by the Hydraulic Filtration Team.

 

Find more related articles here:

Optimising Feed Rate in the Fight Against Cold Corrosion

The Importance of Condition Monitoring to Your Business

Meeting New Sulphur Limits for Marine Fuel Oil

Bunker Quality: Why Changes to ISO 8217 Increase the Need for Condition Monitoring

Fuel Monitoring Matters

Do you need to detect ferrous wear particles in machinery? Are you working remotely, onboard a vessel, or onsite in a less than ideal environment? Ferrous wear meters allow users to measure ferrous wear debris in oil samples for condition monitoring in both marine engines and lubricated machinery.

 

Detecting metal particles

The Parker Ferrous Wear Meter (FWM) is a simple, easy-to-use instrument that provides accurate, reliable detection of metal particles in oil samples taken from a variety of types of machinery, including used cylinder scrape down oil, gearboxes and bearings. Monitoring of ferrous wear levels with your oil samples on an ongoing basis allows any deterioration in machine condition to be quickly spotted and corrective action taken, saving you downtime and money, and preventing more serious damage occurring. This versatile unit is ideal for testing and analysing oil samples on-site, on-board or in remote locations where full laboratory analysis is not possible.

Features include: 

• Suitable for testing on-board, on-site or in remote locations.
• Simple, easy to operate instrument requiring minimal training.
• Direct reading in PPM on the LCD screen. 

 

The FWM is constructed using a sophisticated magnetometer adapted for field applications. A 5-millilitre test tube, filled with the sample, is placed directly in the hole in the instrument and its metallic content, in PPM, is displayed on the screen in less than 2 seconds. 

By taking ferrous wear measurements over time, any increase in wear levels can be monitored and appropriate actions taken to mitigate any damage. Machinery degradation can be observed as it happens and machines serviced as and when they need to be, rather than on a time or hours of operation basis, saving costs and manpower.

 

    Performing a ferrous wear test

 

Each ferrous wear meter is supplied with three check standards to verify the product on a regular basis. In this example, 
the 972 - 922 PPM ferrous content sample is being used. 

 

 

 

 

Step 1

As per the on-screen instructions, insert the sample into the FWM for approximately one second, then remove. The result will be displayed on the screen for comparison against the check standard.

 

 

 

 

Step 2

Begin by agitating your oil sample for approximately 30 seconds. Fill a 5-millilitre test tube to within 5-millimetres of the top with your oil sample. For each test, use a new test tube.

 

 

 

 

Step 3 Insert the oil sample into the ferrous wear meter for approximately 1 second. Then remove. 

 

 

 

 

 

Step 4

The results will display shortly after removal.

 

 

 

 

 

 

Watch this step by step video for complete instructions:

 

 

 

To learn more about the Parker Ferrous Wear Meter, download our datasheet.

 

 

 

 

 

 

 

Please visit our Hydraulic and Industrial Process Filtration Division EMEA for additional information.

 

This post was contributed by the Hydraulic Filtration Team.

 

Find more related articles here:

Optimising Feed Rate in the Fight Against Cold Corrosion

The Importance of Condition Monitoring to Your Business

Meeting New Sulphur Limits for Marine Fuel Oil

Bunker Quality: Why Changes to ISO 8217 Increase the Need for Condition Monitoring

Fuel Monitoring Matters

Carbon dioxide (CO2), a colorless, odorless, noncombustible gas, is widely used in the food and beverage industry during the bottling process as a carbonation agent for soft drinks, beer and sparkling water. CO2 is at risk of contamination from leaks, insufficient processing, transportation, storage and handling, all of which can take place multiple times before reaching its point of use in the production plant. Contamination is a real problem for manufacturers as it can result in off-flavors and odors, spoilage, changes in appearance, product recalls and damaged reputation. That's why many beverage producers are taking measures — such as installing a Parker PCO2 Quality Incident Protection System — to ensure CO2 purity and avoid the serious impact of quality incidents on their businesses. 

To help you learn more about the Parker PCO2 system, we've compiled a list of our top frequently asked questions.

 

 

Download the FAQ sheet to read all 25 FAQs, including information on installation, sizing, FDA approval and filtration. 

 

 

 

 

Top FAQs on the PCO2 Quality Incident Protection System   1. What is PCO2?

The PCO2 is a static adsorption bed constructed from specially selected adsorbents that are designed to remove trace contamination from CO2 to guarantee gas quality so it remains within industry and company guidelines. The system prevents detrimental consequences to the finished end beverage, the producer's reputation, and their bottom-line. 

The  PCO2 designed as a quality incident protection device, meaning that it will treat out-of-specification CO2 to return it back to specification (within the limits of the specification). The PCO2 is not designed to constantly purify poor quality CO2 (not allowing the beverage producer to lower the incoming CO2 specification).

2. Why do I need a PCO2?

CO2 is produced from a wide variety of processes with differing contaminants. Some of these remain in the gas after treatment at the gas recovery plant. There have been some publicised incidents where poor quality gas passed all the way through the supply chain and into the beverage. To prevent a repeat occurrence of these quality incidents, bottlers are implementing in-line, on-site protection, in addition to tightening controls at the CO2 suppliers.

3. What is a quality incident?

This is where a delivery of out-of-specification CO2 has been made to the plant or where CO2 has been contaminated on-site during the production process and fails to meet recommended standards.

4. What is the specification for beverage CO2?

ISBT (International Society of Beverage Technologists) & EIGA (European Industrial Gas Association) both have International recommended standards. In these standards, potential contaminants are named with a critical PPM limit of acceptance.

• Total Volatile Hydrocarbons (as Methane)
• Total Aromatic Hydrocarbon
• Acetaldehyde
• Total Sulphur (excluding SO2, as S)

5. How much contamination will the PCO2 protect against?

The PCO2 purifier will treat CO2 with up to 10 times the ISBT / EIGA levels of the named contaminants for a specified quantity of processed CO2 gas.

6. How do I know when we have had a quality incident?

Many plants will find this very hard to observe if they do not have a CO2 analyser or gas inspection process on site. Most plants take the quality assurance (QA) certificate from the gas supplier as their goods inwards inspection. To improve monitoring of gas quality, many plants are purchasing online CO2 analysers in addition to purifiers.

7. What can I expect to see when plants have analysers fitted?

In most cases, the gas will be clean and have very low levels of monitored contaminants. Under these conditions, there will be very little difference between inlet and outlet concentrations. In the event of a contamination spike, the purifier will remove it.

8. Should I change my elements after a quality Incident?

Yes, always.

9. Who needs a PCO2?

All producers and bottlers of beverage products, including:

• Soft drinks
• Beer
• Carbonated water

10. How does the PCO2 work?

The three-layered adsorbent bed adsorbs contamination as it flows through. The three materials preferentially adsorb differing contaminants thus providing effective protection against a wide spectrum of potential contaminants.

11. Can the cartridges be regenerated?

No, although some companies may claim to be able to recover adsorbents and regenerate them, we are trying to remove contaminants to parts per billion levels and any trace residues may inhibit future performance. Additionally, many industrial processes for regenerating adsorbents ay actually add contamination to the PCO2 cartridges. 

12. Where should I install the PCO2?

The purifier treats vapour phase CO2, so it has to be installed downstream of the vaporiser (evaporator), with a maximum approach temperature of 40°C. Some plants have installed the purifiers close to the carbonator, while others have chosen a central point close to the evaporator for complete site treatment. The Parker PCO2 is suitable for either option. The PCO2 is also suitable for external installation.

 

Download the FAQ sheet to read all 25 the FAQs, including information installation, sizing, FDA approval and filtration. 

 

 

This blog was contributed by Danny Silk, product manager, specialist filtration, Parker Gas Separation and Filtration Division, EMEA.

 

 

 

 

 

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