Knowledge

BUSINESS CHALLENGES

• Dead Volume: 5 to 10 % of product loss per batch in formulation and filling area.
• Drainage Limitations: the filtration process configuration made line drainage impossible.
• Filtration Time: Average filtration cycle exceeded 2 hours on average per batch, limiting throughput volume.

SOLUTION

• Filter Sizing and Process Optimization
  We performed filter sizing study to decrease the throughput filtration time without compromise on quality.
• Downstream Vent Filtration
  We applied a vent filter downstream, enabling complete drainage of filling line and recovery of 98% of dead volume.
• Filter Media Selection and Validation
  Our lab scale trials identified the optimal Capsule with PES filter media and pore size, improving filtrate quality.

RESULT AND BENEFITS

• 50 % decrease in filtration time
• 98 % dead volume recovered
• Improved filtrate quality
• Faster and efficient batch

Download Success Story - Reducing Fitration Time and Recovering Dead Volumes

BUSINESS CHALLENGES

• Slow Delivery: The existing supplier’s lead times were creating recurring bottlenecks.
• High MOQ: Rigid MOQ requirements forced excess stock holding tying up capital, creating financial impact.
• Limited Flexibility: Existing SUS setup made it difficult to adapt to changing process requirements.

SOLUTION

• SUS Process Review:
  We conducted a full review of client’s Single Use process to identify and eliminate the pain points.
• Configuration Optimisation:
  We redesigned SUS configuration to guarantee high-quality yield with significantly reduced delivery times.
• Flexible, User-Friendly Design:
  The SUS were tailored to meet the process requirements of client increasing flexibility and adaptability, with no MOQ constraints adding to cost being saved.

RESULT AND BENEFITS

• Shorter delivery and operating lead times of 6 to 8 weeks
• Simplified user-friendly process
• Reduced cost of excess stock, increasing financial savings of 25% per annum
• Increased flexibility to adapt to change

Download Success Story - Flexible Single Use Systems, Shorter Lead Times