Dry Screw Vacuum Pumping System for Active Pharmaceutical Ingredients (API) Application

For obtaining the pure derivative, repeated loading and distillation of the initial raw product is carried out. Traditionally, a steam ejector vacuum system is used for this purpose which involves a lot of parameters to be optimized. However, the number of cycles varies because of fluctuation in vacuum conditions. In addition, factors such as operator handling which varies from person to person result in variation of number of cycles for each batch. If the steam ejector vacuum pump is replaced by the oil ring vacuum pump, it is found that oil contaminates the final product. So, the oil ring vacuum pump was not suitable for this process. Hence the use of Dry screw vacuum pump for the operation is preferred.

After switching over to the dry screw vacuum pump, consistency in the number of cycles and vacuum level is observed for obtaining the pure derivative. During Evaporation process, crystals are formed whose nature differs for each batch (sometimes fluffy and sometimes crystalline) when wet vacuum pumps are used. This results in lump formation for some batches. With use of dry vacuum pumps this problem can be eliminated due to uniform variation of vacuum level which results in uniformity in temperature variation. This results in consistent output for each batch.

In reference to API industries, the cost savings on parameters like Effluent treatment, Solvent recovery, power consumption etc are quite significant when Dry screw vacuum pumps are used. This results in overall reduction of production cost. It is observed that Effluent generation is not present in Dry vacuum technology due to the absence of water circulation. Further, we are able to recover the solvent which in the wet vacuum system mixes with water.

In addition, the batch processing time decreases significantly when Dry vacuum technology is introduced. This can be attributed to the fact that in earlier processes, maintenance of uniform vacuum over the entire process is difficult thereby resulting in fluctuations and degradation of circulating water. This aspect was taken care of with the advent of the dry vacuum system. Further, the level of vacuum and throughput can be dynamically controlled as per process requirement, using variable drive which also saves energy.

The replacement of the Ejector system with Dry vacuum pump results in significant reduction in yearly maintenance cost. In wet technology, the constant interaction between circulating water and product vapours result in the acidic nature of circulating fluid which tends to corrode the inner components of the pump. This results in regular servicing of the wet vacuum system thereby increasing the maintenance cost. All these aspects are absent in Dry vacuum systems thereby reducing the maintenance cost.

Based on the inputs provided by one of our valued customer who is running the plant for 300 days for production of Methyl piperidine derivatives, the annual savings of effluent treatment, solvent recovery and power consumption after switching to Dry screw vacuum pump amount to nearly Rs 3 crores (about 4 lakh dollars annually). Similarly, the additional revenue generated annually due to increase in the number of batches amounts to about Rs 37 crores (about 50 lakh dollars).

In India many API grade companies manufacture products like Methyl Piperidine derivatives, Benzyl Piperidine derivatives etc. For better yield and cost saving, Dry screw vacuum pump is a good alternative. With subsequent research and development, the cost of the pumps can be reduced and this will cater to small, medium and large scale industries for their overall growth.

The Superscrew dry vacuum systems offered by Everest Vacuum have proven to be a good alternative to reduce the manufacturing cost, ETP treatment, power consumption and improve the overall yield. I believe we can get similar results for your and other companies as well. To see how we can help your business as well, please contact us. One of our experts shall connect with you to discuss this further.