Pharmaceutical manufacturer increases productivity by over 500%
A leading pharmaceutical manufacturer produces over 250 high-value, sterile active pharmaceutical ingredients (APIs) including Octreotide (a peptide hormone medication). These ingredients are the main components within medicines, providing the required health effect.
The API manufacturer uses aseptic manufacturing to produce microsphere powders. These tiny, spherical particles, ranging from 1 to 1,000 microns in size, form a complex drug delivery system for APIs.
After the initial production stages, the manufacturer sieves the pharmaceutical powders at 71 microns using an ultrasonic sifter within a sterile and controlled environment.
However, the manufacturer was unable to produce enough microspheres to meet customer demand. The capacity of its ultrasonic sifter was limited to 1.5 kilograms per hour and therefore unsuitable for scaling production.
The manufacturer researched alternative sterile and GMP-compliant screening solutions and discovered our range of aseptic powder handling applications. After discussing the options with our sales engineer, the API manufacturer chose to purchase our Russell Compact Sieve® MS400 with a side-mounted ultrasonic probe.
Since installing the aseptic vibratory sieve, the manufacturer has seen its productivity increase by over 500%. Their screening capacity for APIs is now 10 kilograms per hour, compared to 1.5 kilograms per hour.
By using our screening technology, the manufacturer has reduced operator handling by 30 to 40% making the process safer for staff. With gentler handling and fewer interventions, the manufacturer has lowered its product loss.
Further benefits include lower consumable and utility usage, due to less demand for autoclaving energy and steam, and improved compliance with isolator VHP cleaning protocols.
About Russell Finex
We are the only manufacturer in the world that makes our own screening and filtration equipment alongside ultrasonic mesh deblinding systems. We do this for virtually every industry around the world and, with over 90 years of experience, we’ve helped the process industry with measurable impact.
We partner with customers to help them enhance their production lines. By combining high-quality equipment, deep expertise, and the ability to customize solutions, we deliver results while acting responsibly and ethically toward both our customers and the environment.
Contact us today to learn how you can benefit from our sieving solutions.
What our customers say
“The Russell Compact Sieve with externally-mounted ultrasonics allowed us to reliably screen sterile API powders inside an isolator, meeting stringent aseptic standards. The design eliminated the need to autoclave the probe, saving us hours per batch and simplifying validation. With high-value APIs like microspheres, this efficiency is crucial.”
