Pneumatics in Pharma – Introduction, Applications and Advantages

Introduction to Pneumatics

Pneumatics is a science that incorporates compressed air for various process functions, machine functionality and activating various components. In industrial applications, it is an alternate method to use electrical energy for supported functions and operating machine component, provided the components supports the application of compressed air

Its central part is its energizing or activation part, such as a sealed cylinder. Compressed air drives the activation part, which is then used to produce the motion in the attached part of the machine or process. Modern pneumatic systems allow multi-directional movement, allowing better and more precise control of the overall machine operation. 

Today's pneumatic system can be easily and effectively integrated with most automation components, such as PLCs and proximity sensors. This enables pneumatic systems to adapt easily to various process requirements, making them more convenient with most automation-based machinery.

Pneumatics in the pharmaceutical industry

Pneumatics is an integral part of the pharmaceutical industry, where it drives critical and essential equipment and instruments for a variety of processes. They are used in different departments, such as manufacturing and packaging, to effectively complete the underlying process. 

Pneumatics in pharma processes have unique advantages, such as safety, quality and purity, that cannot be achieved through traditional electrical based systems. These components also offer high degree of accuracy, offering more preciseness, which is often required.  

What are the advantages of using Pneumatics in the pharmaceutical industry

Some advantages specific to the pharma industry include the following

High accuracy

Pharma processes require a high degree of accuracy. For example, the fill volume must be within a specified range during filling. Otherwise, it could become dangerous to the patient's life, and lead to regulatory actions. 

Pneumatic components can be easily programmed or customized to accurately perform the desired pharma process. Their driving component , such as the cylinder, can be precisely controlled in accordance with the application requirements. 

Corrosion-resistant metallic design

Given the criticality of the process being carried out, cleanliness is an integral requirement of the pharmaceutical industry. Different mechanisms implement cleanliness, and one of many is the requirement of a surface finish, such as using corrosion-resistant metallic components for product contact parts. 

Almost the entire product contact pneumatic component is made up of pharma grade materials, such as corrosion-resistant.  This feature help protect degradation and protect from being affected by pharmaceutical product chemicals, maintaining the highest degree of cleanliness for a longer period.

Another advantage is that pneumatic systems are easy to clean, requiring fewer or no tools, chemicals, or other cleaning agents. This becomes essential for small, and especially for harder-to-reach, pneumatic components. 

Increased Overall Equipment Effectiveness

Overall Equipment Effectiveness (OEE) describes how well a particular piece of equipment is performing, and it is a function of availability, performance, and quality. In the pharmaceutical industry, increased OEE helps a pharmaceutical manufacturer increase its productivity, product portfolio, and market share. 

Pneumatic components can help pharma manufacturers increase their OEE in several ways. It can help manufacturers 

· Attain their production target by making accurate products, thereby reducing errors and the underlying delay in production.  

· Pneumatic components can operate with minimum energy requirements, such as those used for low voltage applications, which help decrease the energy requirement and increase cost effectiveness of the entire equipment or machine.

Easy Placement

Thanks to their small sizes, pneumatic components such as valves, actuators, and their actuators can be easily placed in the machine and its relevant panels. They do not require a huge space and can be easily adjusted without investing much in the machine design.

The pharmaceutical process requires several different accessories, such as furniture, dedicated instruments, and mechanical structures, in their respective rooms or areas. Environmental conditioning accessories, such as HVAC, are also part of the area. Although manufacturers design their machines within the allowable limits, personnel often face the challenge of an abundance of these accessories, with that too in a limited area and budget. 

With pneumatic components, adjusting and settling in an existing machine becomes possible, without requiring more space for panel placement and components inside the machine.

Customized solution

Pneumatic components can be customized for a number of applications in the pharmaceutical industry. They can be used in critical applications, such as product filling and packaging, and in more generalized operations, such as door opening and closing. All these applications can be performed within the range of products available from different suppliers. 

Easy to integrate with industrial automation

Industrial automation is becoming essential for today's processing industry, and no industry can run without it. The ability of pneumatic components to integrate with industrial automation makes them an essential part of most process industry machines. 

Today's pneumatic components can be easily integrated with industrial automation components, such as Programmable Logic Controllers and sensors. This provides a convenient way of harnessing the power of pneumatics and industrial automation in process equipment.

Pneumatic components activate or energize to perform the desired functionality in response to the various control signals from the main controller, or PLC. Additionally, sensors, such as reed switches, provide feedback to the main controller that can accurately actuate pneumatic components. 

Application of Pneumatics in the Pharmaceutical Industry

Let's discuss how it is being used in the pharma industry

Filling Operations

Filling operation in pharma industry is used to fill liquid & injectable into their respective containers with accurate filling dosages and at desired speed. 

Pneumatic pumps are an integral part of the pharmaceutical industry's filling operations. They can provide accuracy in filling operations, keep the design simple, and ensure that filling operations remain safe from contaminants and the remnants of previous products. These pumps require less maintenance and can be easily managed with limited resources.

Different filling mechanisms exist, but generally, they contain a mechanical driver that activates under the influence of compressed air. A vacuum make–break action is performed to complete the liquid filling process into the container. 

 Some common types of pneumatic pumps used in the pharma industry include, but are not limited to 

· Piston Pumps—as the name implies, they consist of a piston that moves under the influence of compressed air. As it moves, it makes and breaks a vacuum, filling the liquid into the attached container.

· A diaphragm pump uses a diaphragm to make and break a vacuum under compressed air's influence. 

· Peristaltic pumps consist of a roller that continues rotating under the influence of compressed air. The liquid is moved forward under the pressure of rollers in the tube. Its main advantage is that product does not comes in direct contact with the any of pump’s part.

Packaging Operations

Packaging is an integral part of pharma operations, where the product is packed in its packaging material using different packaging machines. Pneumatic components are integral to the packaging machine operation, and different parts operate with the help of pneumatic components. 

In packaging machine, different processes, such as product placement, sealing and cutting are performed under the action of pneumatic components. Examples of these components include valves, regulators, accumulators, filters, and tubing.

Some areas where pneumatic components are used in packaging include, 

· Blister formation— In blister packaging machine, cavity is formed under the influence of vacuum. When a specific portion of forming foil is adjusted  on the vacuum plate, different pneumatic components, such as valves and tubing, facilitate vacuum formation. 

· Stage advancement—In packaging machines, packaging is carried out in different stages. After the completion of one stage, the packaging material is advanced to the next stage for further processing, such as cavity formation, filling, and sealing. This material advancement is performed with the help of pneumatic components. A pneumatic cylinder grips the under-processing packaging material and takes it to the next stage until the final station. 

· Controlling the flow of packaging material —Pneumatic components are used to control the flow of packaging material in the packaging machine. Pneumatic control gates installed in the respective channel allow or disallow the material flow, depending upon the process requirement

Pneumatic Conveyors

Conveyors are an essential part of the pharmaceutical industry, transporting material from one department to another or from one part of an area to another. 

A pneumatic conveyor is used to transport bulk material from one area to another under the influence of a pressure differential. In this mechanism, the sending and receiving points are connected through large pipes. The material is either pushed from the sending side or sucked from the receiving point through a pump.

Air Motors

Air motors are pneumatic components that rotate under the influence of compressed air. They do not have electrical components and are constructed with mechanical pneumatic parts. 

As the compressed air flows through the air motor, it starts rotating under its influence. The speed of the motor is directly proportional to the pressure of compressed air – the higher the air pressure, the faster it will rotate. 

In the pharmaceutical industry, air motors drive rotary machine parts such as mixers. They are also used where explosive material is a part of manufacturing process. Because, these explosive materials can be dangerous in the presence of an electrical current, such as electrical motor. Air motors prevent the dangers associated with the electrical energy.

About the Author:

Muhammad Asim Niazi has a vast experience of about 11 years in a Pharmaceutical company. During his tenure he worked in their different departments and had been part of many initiatives within the company. He now uses his experience and skill to write interested content for audiences at PharmaSources.com.