Approximately 500 billion liters of water are used by pharma companies every year. Where traditional water purification methods leave a carbon footprint for future generations to suffer, sustainable water purification systems focus on minimizing consumption and reducing waste.
As environmental consciousness is rising more than ever, pharma companies that produce massive amounts of waste are looking forward to integrating these solutions and actively achieving their sustainable development goals.
If you wonder what are the critical features of sustainable systems, check the list below:
A sustainable water purification system is designed to consume less energy than traditional methods. One can also choose to power water purification systems with solar panels to save energy.
As we reduce the usage of harmful chemicals for water treatment, the efforts to treat wastewater will also be reduced. One can rely on ethylenediamine-N, N’-disuccinic acid (EDDS), a biodegradable chelating agent to bind and remove heavy metals from water. Unlike traditional chelating agents like EDTA, EDDS is more environmentally friendly as it breaks down more readily in natural environments.
Peracetic acid is another alternative to chlorine for disinfection. It is an organic peroxide compound highly effective against a broad spectrum of microorganisms. PAA breaks down into environmentally benign acetic acid (vinegar) and water, making it safer and greener.
Technologies like zero-liquid discharge (ZLD) ensure all water is treated and reused while leaving no waste behind. A zero-liquid discharge system can help you reduce water waste by up to 90%.
Simply switching to solar power, Pharma companies can reduce their carbon footprint by 50%. For example, a 100 kW solar installation can offset approximately 70 tons of CO₂ emissions annually, equivalent to the carbon sequestered by 1,600 trees over ten years. As per the studies, a wind-powered desalination system can save up to 30% of energy.
Here’s a list of innovative technologies that are at play in sustainable water purification systems:
EDI systems produce high-purity water by removing ionized species through electrically driven processes. In contrast to traditional ion exchange methods, an EDI system eradicates the need for chemical regeneration and reduces chemical waste by up to 90%. EDI systems can achieve water quality with a resistivity of up to 18 MΩ·cm, which is one of the stringent requirements of the pharmaceutical industry.
At TSA, we offer Purified water generation systems with Advanced closed-loop recirculation systems for sustainable operations with optional automation of sanitization and sterilization processes. Our high-purity water treatment solutions incorporate continuous electrode-ionization to produce high-purity water that surpasses the most stringent standards in the world!
UV rays are highly effective in inactivating bacteria and viruses and can achieve a 99.99% disinfection rate (4-log reduction) of microbial load in pharmaceutical water. A UV disinfection system proves to be a better alternative to chemical disinfectants as it minimizes the formation of harmful by-products.
It is one of the advanced and celebrated oxidation processes that can remove up to 99% of organic contaminants and pathogens. Ozone is a powerful oxidant that decomposes into oxygen, thus leaving no harmful residues behind. With Ozonation, you can reduce up to 70% of total organic carbon (TOC) levels.
As the name suggests, a ZLD technology eliminates all liquid waste from water purification processes by recovering up to 95% of wastewater as purified water. This highly efficient system reduces the need for fresh water, and in the pharmaceutical industry, it can decrease water consumption by up to 60%.
Besides saving the environment, Pharmaceutical companies also benefit from tax incentives, grants, and subsidies, which can reduce capital costs by up to 30%. By incorporating sustainable water purification systems, companies can achieve compliance with environmental standards and avoid potential fines while improving their corporate social responsibility (CSR) profile.
As we end the discussion on the significance of incorporating sustainable water purification technologies in the pharma industry, the challenges must also be addressed. In addition to the initial costs of these new technologies, maintenance costs and the requirement for technical expertise become a roadblock.
TSA is a one-stop solution where we empathetically listen to your problems and craft cost-effective, sustainable water purification systems.
Reach out to us now for a sustainable future!
Conductivity measures a water's ability to conduct electricity, indirectly indicating the presence of dissolved ionic contaminants.
Pure water itself is a poor conductor of electricity, lacking the charged particles necessary for efficient current flow. However, the presence of dissolved salts, minerals, and some organic matter disrupts this neutrality. When an electric field is applied to the water, these dissolved compounds dissociate into charged ions (cations and anions). Because pure water molecules (H2O) are neutral, these ions migrate toward the oppositely charged electrodes, facilitating the flow of electricity. The more ions present, the higher the water's conductivity. Thus, high conductivity can signal issues like high minerality or industrial waste contamination.
Within the pharmaceutical water production process, conductivity monitoring is crucial at various stages:
Real-time conductivity monitoring allows for immediate detection of any deviations in these critical stages, safeguarding water quality throughout the entire production process and ensuring consistent delivery of pristine pharmaceutical water for the production of vital medications.
Total organic carbon (TOC) represents the total amount of organic carbon present in water. Excessive TOC can indicate the presence of organic contaminants like decaying organic matter, microorganisms, or industrial byproducts. Even trace amounts of these contaminants can significantly impact the quality and safety of pharmaceutical products.
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TOC monitoring is particularly important for:
Ultrafiltration (UF) Permeate Monitoring: The UF membrane works as a microscopic sieve. Its pores are specifically sized to allow water molecules and tiny dissolved particles to slip through while prohibiting larger contaminants from passing. This selective filtration process removes unwanted organic molecules like decaying matter, microorganisms, and industrial byproducts. Real-time TOC monitoring of the treated water (permeate) following the membrane serves as a vital performance indicator. A sudden spike in TOC could signal a compromised membrane or organic matter breakthrough, prompting corrective actions to maintain the critical purity of pharmaceutical water.
On-line continuous TOC monitoring provides full spectrum insight into organic carbon levels and potential excursions, enabling proactive adjustments to treatment processes and guaranteeing consistent water quality.
Within the realm of pharmaceutical water production, the term "bioburden" is of critical significance. It refers to the quantitative measure of the total number of viable microorganisms, encompassing bacteria, fungi, and even some protozoa, present in a given water sample. A high bioburden signifies a potential health risk associated with the intrusion of these unwanted microbes. Furthermore, it can indicate inefficiencies within the water purification processes designed to eliminate them.
Monitoring bioburden is paramount for:
The Entire Water Production Process: Regular bioburden assessments throughout various stages of the water purification process are crucial. This continuous monitoring helps identify potential sources of microbial contamination and ensures consistent low microbial levels are maintained within the entire water system.
Post-Disinfection Stages: Disinfection processes, such as ultraviolet (UV) treatment or ozone application, are employed to eliminate microorganisms from the water. Bioburden monitoring after these disinfection stages serves as a critical verification step. A low bioburden reading following disinfection confirms the effectiveness of the chosen technique in achieving microbial inactivation. Conversely, a high bioburden reading indicates a potential breach in the disinfection process, necessitating investigation and corrective actions.
Storage and Distribution Monitoring: Functioning as the final line of defense, bioburden monitoring is conducted at storage tanks and within the return loop. The focus now is on detecting microorganisms that might have snuck through the system. The best place to measure for this is in the return loop, since it’s measuring the water already produced and at the same time that's being used. Regular monitoring here and taking any necessary corrective actions ensures product safety and compliance with regulations.
Rapid and constant bioburden monitoring empowers companies to implement preventative measures to control microbial growth. This proactive approach minimizes the risk of contamination events and ensures reliable adherence to stringent microbiological quality standards set forth by pharmacopeias like the USP.
Dissolved ozone (O3) emerges as a powerful weapon in the fight for microbiologically pure pharmaceutical water. Its strength lies in its unique chemistry: acting as a potent oxidizing agent, ozone disrupts the integrity and kills bacteria and viruses by readily reacting with electron-rich molecules in their cell walls. This oxidizing power extends to even chlorine-resistant foes like cysts and certain viruses. Moreover, ozone boasts rapid disinfection kinetics, offering swift action compared to some traditional methods. Finally, it aligns perfectly with the "no added substances" principle as it naturally decomposes back into oxygen (O2) upon exposure to ultraviolet (UV) light, leaving no residual concerns in the treated water.
Monitoring dissolved ozone is essential for the following:
Disinfection Process Control: Maintaining optimal ozone concentration is a delicate balancing act. While a level too low might leave microbes unfazed, excessively high levels can generate harmful derivatives. By considering water quality parameters like pH, temperature, and organic content, adjustments to ozone dosage or contact time can be made to ensure the most effective disinfection possible.
Compliance with Disinfectant Residual Regulations: Pharmacopeias and regulatory bodies set limitations on residual disinfectant levels in treated water. For ozone, these limitations aim to balance the need for microbial control with minimizing potential byproduct formation. Continuous dissolved ozone monitoring allows for adjustments in the disinfection process to maintain residual ozone levels within acceptable limits.
Real-time dissolved ozone monitoring provides continuous insight into ozone levels, enabling operators to leverage real-time data to immediately fine-tune ozone dosages or contact time, ensuring effective disinfection and regulatory compliance.
For decades, the cornerstone of pharmaceutical water quality control has been the "grab sampling" method. Here, water samples are meticulously collected at predetermined intervals and whisked away to a laboratory for analysis. While this approach offers valuable data points, its inherent limitations can pose significant threats to water purity.
The time between sample collection and receiving results can be substantial. This critical lag can mask transient contamination events or quality excursions between sampling points. By the time an issue is identified, a significant volume of potentially contaminated water may have already been produced.
Furthermore, grab sampling offers a limited snapshot of water quality at a specific time and location. It fails to capture the dynamic nature of water purification processes, potentially missing critical moments of vulnerability to contamination.
Real-time monitoring offers a new era of water quality control, offering a dynamic and continuous window into the intricate workings of pharmaceutical water purification. This approach strategically deploys online analyzers at critical points within the system, transforming water quality monitoring from a reactive to a proactive endeavor. These analyzers function as vigilant sentinels, continuously measuring essential water testing parameters.
At METTLER TOLEDO, we understand the paramount importance of pharmaceutical water purity. Compromises in this critical area can have far-reaching consequences. That's why we offer a comprehensive solution – real-time monitoring of TOC, conductivity, dissolved ozone, and bioburden – empowering you to gain unparalleled control and insight into your water purification process.
With an all-encompassing suite of analyzers, we help pharmaceutical water manufacturers simplify system integration, data management, and operator training to facilitate a smooth transition to a robust real-time monitoring environment. Our proactive approach safeguards water quality, minimizes contamination risks, and ultimately supports the consistent production of drugs and medications.
Contact us to discuss your requirements of pharmaceutical water system. Our experienced sales team can help you identify the options that best suit your needs.