The reactor is one of the elements found in all, or at least most, pharmaceutical production lines (especially in the manufacture of liquids). Being one of the main actors of the lines, a good design is essential to avoid unexpected events and to ensure a good operation.
When we design a reactor, we must take into account several aspects before launching the order to a manufacturer. It is important to identify the basic criteria that will define the geometry, size, materials, etc. of the reactors.
The first step is the sizing of the tank. To do this we must increase the focus of vision and look at the whole process to know the optimal size of the manufacturing lot. The global analysis of the whole manufacturing line goes from the manufacturing reactors to the packaging line: the speed of the packaging line, the different formats to be packed, the flow/pressure requirements of the filler, the maximum time we have defined between cleanings/sterilizations, etc. With the analysis of all these data we will be able to propose an optimal size for the tank.
One of the key factors will be to analyse the maximum and minimum size of the batch to be manufactured in the same reactor, so that we can guarantee good agitation or maintenance of temperatures or other parameters in all these conditions and at all points of the reactor.
Secondly, it will be necessary to define all the components and additional aspects that we will need to include in this reactor:
- Heating/cooling jacket: depending on the conditions required by the process, a jacket can be fed by steam, cold water or a secondary circuit that is at the right temperature
- Agitator: the most used in pharma is the magnetic one, since it allows an easy cleaning and avoids the physical contact between the inside and the outside of the tank. Its main disadvantage would be its high cost and the limitation of agitation in large tanks. Upper or lower vertical agitators are also used depending on the requirements (standard vertical agitator, Rushton turbine for bioreactors, turrax for dispersions, etc.)
- Instrumentation: measurement of level, temperature, pressure, pH, oxygen concentration, etc.
- Sampling port
- It is important to define whether the tank should be sterilized or not and whether the transfer of the product to the filler is done with a pump or by pneumatic pressure, since this will determine the calculation of the thickness of the walls of the reactor
- Material: typically, stainless steel with a controlled roughness, but depending on the products to be manufactured other materials could be used
It is important to define whether the tank should be sterilized or not and whether the transfer of product to the filler is done with a pump or by pneumatic pressure, since these two factors have a great influence on the calculation of the thickness of the walls of the reactor.
All these points will determine the geometry of the reactor. With this and the dimensioning we would be able to start the production. The study of all these factors requires experience and dedication, which we can offer from Klinea.
If you are interested in knowing more about reactor design and how we can help you, contact us: firstname.lastname@example.org
- Posted by Klinea
- On 16 September, 2020
- 0 Comments