Membrane Filtration System
Membrane filter manufacturers in India commonly produce membrane filtration systems for sterile or non-sterile filtration of pharmaceutical preparations within the industry. They are also required in the semiconductor industry, where the manufacturing operations need to be carried out on the scale of nanometers, equivalent to the pore-size of some of the finest microfiltration cartridges.
Typically, membrane filter systems are utilized for filtering small volumes of pharmaceutical solutions, including ophthalmic solutions, through sterile membranes such as those with 0.45 or 0.2 micron ratings. These ratings, in the case of PTFE membrane filters, are absolute, as opposed to ratings of powder-sintered metallic filters or even PP membranes. They can be, and need to be integrity-tested before and after every batch of filtration, in order to guarantee the sterility of the filtrate.
These membrane filters come in different forms, although the most common ones are as follows:
1. Membrane cartridges
2. Capsule filters
3. Syringe filters
4. Membranes along with membrane holders
1. Membrane cartridges
Membrane cartridges are themselves comprised of multiple components themselves -
a) The membrane itself
b) Cage for protection of the membrane
c) Core support
d) O-ring
d) End cap
d) End cap inserts
All of these can be made with different materials of construction, which affect their performance and reusability. For example, cartridges with PP membranes have a maximum continuous operating temperature of about 60 C, owing to their lower softening point as compared to those with PTFE membranes, whose continuous operating temperatures can be in the range of even 180 C.
Similarly, in semiconductor applications where highly corrosive gases need to be filtered, only cartridges made completely of fluoropolymers are compatible.
It is imperative that the customer gives as much detail as possible with regards to the process and the cleaning conditions to the filter manufacturer, to enable them to give a membrane cartridge with a compatible combination of all of these components.
2. Capsule filters
They are disposable, filter + housing systems, used for small volume filtration. Again, the material of construction along with the porosity of the membrane, decides the use case and cleanability of the filter. Once choked, the entire capsule has to be disposed of and a new capsule has to be fitted.
3. Syringe filter
These are generally single use filters, with absolute rated membranes, used for volumes smaller than those involved with a capsule filter.
4. Membrane holders
Membrane holders often comprise SS316L components with internally mirror-polished surfaces. Within the system internals, you'll find a perforated support and a flow distribution plate, while tightening is achieved with six specially provided bolts. Sealing is facilitated by food-grade silicone O-rings.
Additionally, membrane holder filtration systems can be configured to include cleanable SS316 filter discs, typically with a 2-micron rating. These discs serve as a pre-filtration stage, allowing users to conduct both pre-filtration and sterile filtration in a single pass, enhancing efficiency and convenience.
Features
Membrane filter systems offer a plethora of distinctive features tailored specifically for industrial applications.
These features include:
Precision Filtration: Absolute-rated filter membranes available
Versatility: PTFE membranes enable fluids with a wide range of pH, temperatures to be filtered.
Consistency: Membrane filters can be tested after every batch, guaranteeing the filtration quality
Scalability: Using cartridge-based systems, the scalability is technically unlimited
Cost-effectiveness: When paired with an effective pre-filter, the cost effectiveness of the membrane filtration system can be brought down tremendously.
Easy Maintenance: Cartridge membrane filters offer easy maintenance, as they can be disposed off and new cartridges fitted when the differential pressure of the system exceeds the specified limits.
Applications
The application of membrane filtration systems across various industries, including:
Used for sterile filtration of pharmaceutical preparations.
Utilized for the removal of bacteria from water
Used for purification of chemicals, and removal of impurities, especially in the semiconductor industry.
How does membrane filtration work?
Membrane filtration system works by selectively allowing certain substances to pass through a semipermeable membrane filter while blocking others based on size, charge, etc. The process typically involves applying pressure to a feed solution, forcing it through the membrane.
Size: The porosity of the membrane is a function of the manufacturing process. The porosity decides the scale of the physical barrier offered by the filter to particles in the incoming stream.
Charge: Certain materials like PES are generally low protein binding, while materials like nylon are high protein binding. Thus, depending on the application, the filter vendor has to decide on which filter is most suitable for the client.
Why choose Kumar Process consultants for your membrane filtration needs?
As a prominent global membrane filters supplier to various industries, Kumar Filters provides a variety of membranes and specializes in Microfiltration.
Microfiltration (MF) is a membrane-based process that selectively separates particles and microorganisms from liquids. It operates on size exclusion, retaining larger particles while allowing smaller ones to pass through. With pore sizes typically ranging from 0.1 to 10 microns, MF is effective for removing bacteria, colloids, and proteins. It finds applications in wastewater treatment, beverage clarification, food processing, pharmaceuticals, and biotechnology due to its efficacy, low energy consumption, and ease of maintenance.
Kumar process has extensive experience in the manufacturing of Membrane filtration systems for the pharma sector. We select the filter cartridges that are suitable for the client’s requirements based on their application, considering the porosity rating, flow, operating temperature and pressure, Chemistry of the fluid, etc. Appropriate and compatible pre-filtration systems are given to protect the expensive membrane filter cartridges from choking prematurely. Kumar Process has a filter validation guide for pharmaceutical customers, along with certifications for the materials used in the construction of filter cartridges with regards to endotoxin shedding limits, B. Diminuta retention testing amongst other parameters requisite for filtration of crucial items like injectables, etc.
