Replacing Lenticulars with SupaCarb CP for API decolourisation

Product

SupaCarb CP

Client

European Pharmaceutical CDMO

Application

Decolourisation of new API

Location

Value Added

Process Optimisation

Sector

Pharma

Decolourisation of an API is a common process step typically achieved by either:

1. Introducing carbon powder / granules into the reactors then filtering out downstream

2. Using carbon impregnated lenticular cell filters

3. Using carbon block filters.

The method is often determined by the volume of product being processed and the historical grades of carbon used to decolourise on the legacy production processes.

We recently worked with this client who was looking for a decolourising solution for a new API in the development scale-up phase in the kilo lab.

In small R&D, pilot and kilo labs the use of sintered carbon block filters can prove a far more elegant and cost effective way of decolourising. Benefits includes increased efficiency, reduced waste and improved heath and safety.

The Problem

When developing new API products and the associated production processes it is often the case that existing technology is used. While this can save time it can also hinder process improvements. Traditional methods using loose carbon and lenticular cells have a number of disadvantages. A comparison of these two technologies is provided in the table below:

The Solution

Following discussions with the process engineer on site it was established that the decolourisation stage could be more efficiently addressed using a carbon block format rather than a lenticular cell.

The SupaCarb CP filter is manufactured from an optimised blend of both granular and powdered activated carbon to maximise throughput and colour removal. The integral prefilter layer also helps to extend the life of the carbon block.

SupaCarb Small CutOut-2

In this particular application a 8" diameter lenticular was replaced with a standard 2.5" diameter filter cartridge.

This format has multiple benefits over the lenticular cell format including:

A smaller footprint and higher colour removal efficiency due to the much higher density of carbon in SupaCarb CP compared to carbon impregnated cellulose media
No carbon shedding downstream into the process. The sintered structure combined with a unique resin bonded skeleton ensures carbon particles are not released
Use of standard cartridge format housings, hence reducing installation costs
Ability to improve heath & safety by installing the SupaCarb CP into the SupaClean format
Less consumable waste due to the much smaller size of the filter

Design Flowrates and System Size

This application was sized at 0.8 litres /min/10" length of SupaCarb.

While this application was for relatively small batch sizes in a Kilo lab we have also provided solutions for larger applications, specifically when replacing loose granular carbon.

Following customer laboratory trials comparing the colour removal efficiency of loose carbon vs small segments of the carbon log, the SupaCarb CP was installed on the production line.

The system processes 1m³/ hr of API through two parallel, multi-round housings consisting of 5x 30" SupaCarb CP. Decolourisation is completed in a single pass whereas the solution with loose carbon required multiple passes.

Key takeaways

The use of SupaCarb CP can provide a cost effective, efficient and safe alternative solution for the decolourisation of API's
The standard cartridge format allows the simple implementation of improved operator safety utilising our SupaClean format or our flexible containment solutions

For more information, please contact us using the form below, or give us a call on +44 (0) 1276 670600.