Application Area

Pharmaceutical Ingredients

The efficient separation of particles is critical in the production and processing of pharmaceutical ingredients, especially during the drying, mixing, grinding, micronization, and tablet pressing of synthetic and natural Active Pharmaceutical Ingredients (APIs). These processes demand precise control to maintain product integrity and safety, particularly when dealing with active pharmaceutical particle size reduction.

Spray Drying and Cyclone Separation

Efficient recovery of powders after spray drying can be quite challenging, especially for expensive products and for powders with a small (~6µm) or very small (~2µm) particle size (inhalables).

Pharmaceutical spray drying arrangements typically include a high efficiency cyclone following the dryer, a sanitary bag filter and a HEPA filter at the very end of the line to ensure that no product is ever leaked into the atmosphere.

In this application the cyclone is mostly unavoidable due to its unique hygienic properties. Unlike bag filters, cyclones avoid product contamination with filter fibers and are usually mandatory in pharmaceutical spray drying layouts. Cyclones can swiftly and effectively separate a variety of powder batches without any product cross-contamination since they are readily, fast, and effectively CIPable (cleaned in place automatically). For these reasons, the bag filter, which is positioned downstream of the cyclone to catch its losses, only serves to protect the HEPA filter; the powder it collects is regarded as waste/disposable.

Product losses due to cyclones' low efficiency represent a high cost. Even for a few applications where the losses may not be so costly (less expensive products), they are not environmentally and socially responsible, with waste management being an additional problem to tackle.

Clients need cyclones that maximize powder yield, but are also easy and fast to clean and disinfect to allow for fast batch turnover.

ACS solutions for GMP compliant high efficiency cyclones (HR up to MK families) dramatically reduce losses (down to 1/8 of other cyclones) and achieve unmatched efficiency, even for very fine inhalable products. These can be equipped with state-of-the-art CIP, insulation, heat tracing and many other features. All models are tailor optimized and designed by our team to meet the client's requirements for each installation.

Smaller units are fabricated using break-apart construction, using only tri-clamps for fast and effort free dismantling.

Cyclones in Tablet Pressing and Encapsulation

Tablet pressing and encapsulation processes generate fine dust that can pose health risks and lead to product cross-contamination. Cyclones positioned upstream in the process ensure a steady airflow in local exhaust ventilation (LEV) systems, preventing filter clogging and maintaining optimal pressure. These cyclones effectively capture waste dust, reducing the risk of exposure to hazardous particles and improving overall extraction efficiency.

For processes such as cyclone tablet pressing, cyclones offer a solution to waste powder accounting, capturing lost powder and improving yield when reintroduced into the process. ACS provides a wide range of GMP-compliant cyclones, tailored for tablet pressing and encapsulation. These systems are designed for ease of use, with break-apart construction, tri-clamp fittings for quick assembly and disassembly, and mobile structures for convenient relocation."

Benefits of ACS Cyclones for the Pharmaceutical Industry

- High efficiency in powder recovery: Reduces product loss to as low as 1/8 of typical cyclones.
- Enhanced GMP compliance: Ensures easy cleaning and maintenance, minimising contamination risks.
Improved safety: Protects operators from exposure to hazardous dust during pressing and encapsulation.
- Optimised process performance: Maintains consistent airflow and pressure in extraction systems, improving overall process yield.
- Flexible and customisable: Tailor-designed systems to meet specific client needs in cyclone pharmaceuticals manufacturing.
- By integrating ACS’s advanced cyclones, pharmaceutical manufacturers can achieve superior performance in pharmaceutical ingredients production, ensuring both operational efficiency and product quality.

Explore our successful implementations of cyclone pharma systems in pharmaceutical ingredient processing below.

ACS has a wide range of different GMP compliant cyclone families for tablet pressing and encapsulation both for waste powder accounting and powder recovery, with much higher efficiency than alternatives. Units include a catch pot with a sight glass, a structure with wheels for smooth mobility and are fabricated using break-apart construction, using only tri-clamps for fast and effort free dismantling.

Please check some case studies below.