Professional Documents
Culture Documents
Water
• Water is essential for all life
• categories of users –
• municipal,
• industrial,
• institutional,
• medical,
• commercial
• residential.
water in Pharmaceuticals
– As Solvent in
– sterile products
– non-sterile products
– solid dose products
– washing and rinsing
– Drug Analysis
Pharmaceutical Water
Solvent Drug
Analysis
Cleaning Steam
4
Hydrologic Cycle
• Water evaporates from surface supplies
and transpires from vegetation directly
into the atmosphere.
• It returns to the earth as rain
Acid Rain
Impurities
Dissolved Suspended
Anion
RAW WATER IMPURITIES PROBLEMS
IMPURITIES Patient acceptability, Blocking
dust particle Dust particle of capillary
microorganism
Pyrogen
Gasses (O2, N2, CO2 ) Microorganism Infection
Organic O2 Oxidation of drug
Radical (CO3, HCO3, NO3 etc ) N2
Cations (Ca+2, Mg+2, Fe+2 etc ) CO2
Anions (Cl-1, Br-1, I-1 etc ) Pyrogen Increases body temperature
CO3-2 May react with drug
HCO3-1 May react with drug
NO3-1 May react with drug
Ca+2 May react with drug
Mg+2 May react with drug
Na+1 May react with drug
Fe+2 May react with drug
Cl-1 May react with drug
Br-1 May react with drug
I-1 May react with drug
Inorganic Contaminants
• Calcium and magnesium are probably the two
most common mineral contaminants. They
cause water hardness. Heating or boiling water
can precipitate these minerals leaving behind a
scale deposit.
• 2. Iron and manganese discolor water and can
react with drug products, or act as catalysts in
decomposition processes.
• 3. Silicates may interfere with distillation
equipment.
Inorganic Contaminants
Pharmaceutical Water
NAME DEFINITION
Ca++ No turbidity when 2ml ammonium oxalate is added to 100ml water USP24
NAME USES
Purified water 1.liquid preparation
2.equipment cleaning
3.bulk chemical manufacturing
Sterile purified water Ophthalmic preparation
Water for injection 1.parenterial preparation
2.equipment cleaning
3.bulk chemical manufacturing
Sterile water for injection 1.parenterial preparation
2.equipment cleaning
3.bulk chemical manufacturing
Methods for purification
• Ion Exchange Method
• Filtration Method
• Distillation Method
• Disinfection
Method
• Water Softener:
• Water is softened in a Cation exchange column
where the calcium and magnesium ions are
exchanged for sodium. The sodium then has to
be removed by de-ionization or reverse osmosis.
When the resin reaches its exchange limit, it
needs to be stripped of calcium and magnesium.
This can be done using a brine solution, which
exchanges sodium for calcium and magnesium,
and the cycle starts again.
Water Softener – schematic drawing
"soft" water to deioniser
by pass valve
"hard" water
in
drain
Water Softener:
DIP
DIP
• Principle:
• Ion exchange resin is present in both twin
bed and mixed bed de-ionizer. A twin bed
de-ionizer contains cation exchange resin
and anion exchange resin into two
separate cylinders but mixed bed de-
ionizer contains both the resins in the
same cylinder.
Typical de-ionizer schematic
from water softener
HCl NaOH
6 6
5 5
4 4
3 3
2 2
1 1
Water
must be Cationic column Anionic column Cartridge Cartridge
kept UV light filter 5 µm filter 1 µm
Outlets or storage.
Drain line
Disadvantages:
Danger of microbial growth on Resin
DIP cannot remove most of the
contaminants of water.
More acid- base handling
DIP is not sufficient to produce purified
water.
DIP
• Uses:
• DIP is mainly used as ion separator in a
water purification system. It is an
intermediate process in water purification
system. It is used before Distillation or
Reverse Osmosis unit for partial
purification of water. DIP prevents scaling
and ensures quality WFI
Methods
. Filtration Methods
Semi-permeable
membrane
Feed
water
Permeate
water
water
drain or recycle
Typical 2-stage RO schematic
Water from softener or de-ioniser
Second stage reject water goes back to first stage buffer tank
1st stage buffer tank
Branch First stage RO cartridge
1st stage reject concentrate
Branch
High pressure
pump
Cartridge
filter 1 µm Hygienic pump
Second stage RO water
meets Pharmacopoeia Water returns to 1st stage buffer tank
standards Outlets or storage
Reverse Osmosis (RO):
• Advantages of RO:
• Less chemical handling than ion
exchange
• More effective microbial control than ion
exchange
• Integrity test possible
• Removes most of organic and non-organic
contaminants
• Less energy consumption than distillation
Reverse Osmosis (RO):
• Disadvantages of RO:
• Water consumption higher than IE unless waste-
water is re-used
• Danger of microbial growth on membrane
• Sterilization/sanitization with steam not possible
• No removal of dissolved gases
• Working at high temperature (>65 °C) only
possible with certain types of
membrane
Reverse Osmosis (RO):
• Uses of RO:
• Preparation of purified water that meets Pharmacopoeia
specifications
• Feeding of distillation units– prevents scaling and
ensures quality WFI
• Water for Final Rinse
• Water for Injection – only if permitted by local regulations
• Removal of organic contaminants such as endotoxins
• Operation at 80°C possible
• Sterilisation at 121°C possible
Distillation
• Principle:
• Separation of liquid from solid-liquid mixture or liquid-liquid mixture
by partial vaporization and separate collection of vapor is known as
distillation. Raw water is a mixture of liquid, solid and gases. Boiling
point of water is 1000c. If raw water is heated at 1000c only pure
water evaporates and contaminants are left behind in the reject
water. Vapour is then transferred to a condenser to give
pharmaceutical water.
• Single-effect distillation is the process whereby water is boiled and
the vapour is transferred to a condenser. This is known as a single-
effect still – one boiling pot, one condenser and a collection vessel.
• Multi-effect distillation gives better, more reliable quality PFW and
WFI. Steam is produced and condensed in multiple columns or
“effects”, with the condensate becoming progressively more pure,
thus producing high quality WFI, at better energetical conditions.
Diatillation
• Advantages:
• Less chemical handling than ion exchange
method.
• More effective microbial control than ion
exchange
• Integrity test possible
• Removes most of organic and non-organic
contaminants
• Sterilization/sanitization with steam is possible
• Removal of dissolved gases
Distillation
• Disadvantages:
• Water consumption higher than DIP
unless waste-water is re-used
• More energy consumption.
• It is not advisable to use only distillation
plant for the preparation of pharmaceutical
water due to scaling formation. So Pre-
treatments are essential.
Distillation
• Uses:
• Preparation of purified water that meets
Pharmacopoeia specifications
• Preparation of
• Water for Final Rinse
• Preparation of water for Injection
• Removal of organic contaminants such as
endotoxins
•
Method
Disinfections
• Ozone:
• The chemical formula is O3.This gas is highly unstable,
and is one of the strongest oxidizing agents. It is easily
produced by O3-promoting UV light units, or corona
electricity through O2. It leaves no residue. However,
because it is highly reactive, O3 must be stripped from
the water before the water is used to manufacture
pharmaceuticals. Otherwise it will quickly degrade the
actives. Ozone may be removed by ultraviolet (UV) light
at 254 nanometers, reducing the ozone to oxygen. The
use of Ozone in storage and distribution systems is
growing because of its relatively low capital and
operating costs, compared to hot water generation and
storage.
Ozonator
Disinfectants
• Chlorine:
• The halogen family of chlorine, bromine
and chloramines is very strong, and these
chemicals are very good disinfectants.
However, residues can cause
considerable corrosion. The by-products
of halogen chemical disinfectants can
cause problems if they are not completely
removed from the water.
Disinfectants
• Formaldehydes
• Formaldehyde is the principal agent from the
aldehyde family, but glutaraldehyde has also
been used. The latter has a toxic vapour even
at very low levels so its use is not widespread.
The aldehydes have persistent residues, which
can take so long to flush out of the water that the
system becomes re-contaminated. Ensure that
the company conducts tests for residues before
the water is used for manufacturing.
Disinfectants
• UV light:
• 1.UV light is bactericidal, but water can
attenuate the radiation quickly. The design and
maintenance of the system is important. The
units do not “sterilize” water as is sometimes
claimed; at best the manufacturer can expect
about a 3 log reduction of bacteria for properly
installed and maintained equipment. The lamp
life is often less than 12 months.
UV Light
UV light
Disinfectants
• Heat:
• Heat is the preferred disinfection method because it is safe,
inexpensive, effective and leaves no residues.
• Heat is one of the most reliable methods used to disinfect water
systems, as the problem with chemical disinfectants is achieving a
balance between the risks from microbial pathogens and disinfection
by-products. It is important to provide protection from microbial
pathogens while simultaneously ensuring that disinfection by-
products do not affect the ultimate product.
• The manufacturer must record the time and temperature of the heat
disinfection cycle: > 60oC for purified water for 1 hour or > 70oC for
WFI, continuous circulation. The contact time must be validated.
The inspector should ask for records of this to verify effective
contact time.
Typical water storage and distribution schematic
Hydrophobic air filter
Feed Water & burst disc
from
DI or RO Cartridge
filter 1 µm Spray ball
Optional
Water must in-line filter
be kept 0,2 µm
circulating
UV light
Outlets
Heat Exchanger
Ozone Generator Hygienic pump Air break
to drain
Pretreatment –
schematic drawing
float
operated excess water recycled activated
carbon
To water
valve from deioniser
air filter sand filter filter softener &
DI plant
spray ball
cartridge
filter
centrifugal pump 5 micrometers
air break to drain
« S” trap to sewer
• Principle:
• Water-treatment plants should be designed, constructed,
maintained and validated so as to ensure the reliable
production of water of an appropriate quality. They
should be operated within their design limits.
• All water-treatment systems, including stills, should be
subject to planned sampling, testing, inspection and
monitoring.
• Water should be produced, stored and distributed so as
to prevent microbial growth. This can be achieved, for
example, by constant circulation at 70°C or at not more
than 4°C.
• Components of Water Treatment plant:
• There are various components of a water
treatment plants:
• Raw water collection, storage
• Pre-treatment: Chemical additives, AC filter, Sand
Filter, Water softer
• Main treatment: DIP, DP, ROP
• Post treatment: UV, Cartridge Filter
• Storage & Distribution
Storage and distribution
• Storage and distribution of Pharmaceutical Water
• The storage of highly purified water types is critical
because of the risk of re-contamination by micro-
organisms and other contaminants.
• Good design elements include:
• Closed system with continuous re-circulation at 1-2 (or
more) linear metres per second;
• Hydrophobic vent filters, which can be sterilized and
integrity-tested;
• Burst disc if tank is heated, to prevent the tank collapsing
as it cools; Recirculation via spray ball, to ensure the
tank lid is wet with moving water;
Storage and distribution
• In-line disinfection, by periodic heating,
ozonization or UV;
• Air breaks to drains;
• In-line 0.2 micrometer filter to “polish” the
water in purified water systems
• WFI storage, which must be 70oC or
above, and preferably above 80oC. (No
ozone and filtration in WfI storage and
distribution systems).
Summary
• State what has been
learned
• Define ways to apply
training
• Request feedback of
training session
1/5/2011 96
WATER DISTILLATION PLANT
1/5/2011 97
Pretreatment –
schematic drawing
float
operated excess water recycled activated
carbon
To water
valve from deioniser
air filter sand filter filter softener &
DI plant
spray ball
cartridge
filter
centrifugal pump 5 micrometers
air break to drain
« S” trap to sewer
Water Softener – schematic drawing
"soft" water to deioniser
by pass valve
"hard" water
in
drain
Typical de-ionizer schematic
from water softener
HCl NaOH
6 6
5 5
4 4
3 3
2 2
1 1
Water
must be Cationic column Anionic column Cartridge Cartridge
kept UV light filter 5 µm filter 1 µm
Outlets or storage.
Drain line
Semi-permeable
membrane
Feed
water
Permeate
water
water
drain or recycle
Typical 2-stage RO schematic
Water from softener or de-ioniser
Second stage reject water goes back to first stage buffer tank
1st stage buffer tank
Branch First stage RO cartridge
1st stage reject concentrate
Branch
High pressure
pump
Cartridge
filter 1 µm Hygienic pump
Second stage RO water
meets Pharmacopoeia Water returns to 1st stage buffer tank
standards Outlets or storage
Typical water storage and distribution schematic
Hydrophobic air filter
Feed Water & burst disc
from
DI or RO Cartridge
filter 1 µm Spray ball
Optional
Water must in-line filter
be kept 0,2 µm
circulating
UV light
Outlets
Heat Exchanger
Ozone Generator Hygienic pump Air break
to drain
INCORRECT WATER TREATMENT PLANT
MODIFIED WATER TREATMENT PLANT
Softner
Sand and Carbon Filter
Distillation Plant
Ozonator
Ultrafiltration
DIP