Manufacturing and installation cost of DM water plants
In the pharmaceutical production sector, water is a vital component. In the processing, formulation, and manufacture of pharmaceutical products and medical devices, it is utilised as a raw material, ingredient, and solvent. The quality of water used for each of these uses, however, varies. Water used as a raw material, for example, is subject to more severe purity rules than water used to clean the factory/plant premises. Water quality for pharmaceutical application must still meet a variety of international purity requirements.
Water treatment systems used to create purified water must be built to meet the required quality standards, according to manufacturers. To generate water that is suitable for use in pharmaceutical enterprises, a variety of water purification procedures are used.
Manufacturing process of DM water plants in pharmaceutical industry
1. De-mineralized Water
The process of removing specific minerals from feed water is known as demineralization. Water includes several contaminants and minerals that make it unsuited for use in its natural state. Hard water is a term for unclean water. The internal elements of machinery and systems used in a pure water factory can be particularly vulnerable to hard water. It has the potential to severely erode metal items and cause fast corrosion. As a result, mineral removal from hard water is a critical stage in any filtered water system.
All minerals that cause water hardness are removed, and demineralized water is created. The dissolved minerals and salts are removed using an Ion Exchange method. Minerals with a positive charge are removed by an anion exchange resin, while minerals and salts with a negative charge are removed by a cation exchange resin. This technique softens the water by removing the contaminants that cause it to be harsh. In order to create steam, soft water is commonly utilised in boilers. It's also utilised in other purification plants as a feed water.
2. Purified water
When compared to demineralized water, filtered water is more pure. It's made by putting demineralized water through a second purification procedure before being filtered. To filter water further, methods such as reverse osmosis or UV light purification are used. When soft water flows through the fine filters in a RO membrane, the contaminants are trapped in the filter, leaving only pure water behind. In addition, the tiny filters can remove microbiological pollution from the water.
Purified water is used in pharmaceutical manufacturing facilities to make water for injection, also known as WFI, which is a high purity water used in the manufacture of (injectable) medications. Purified water is produced via multi-column distillation. The feed water is converted to steam in a distillation facility, and the steam is purified using a condensation process.
Purified water must pass a variety of tests for purity, including pH, conductivity, hardness, heavy metals, and microbiological limits. Manufacturers must guarantee that the purified water used in the manufacturing of pharmaceutical goods in their facility complies with USFDA, EU, and ISI requirements.
In the pharmaceutical sector, pure water is utilised for formulation, mixing, diluting, and even cleaning. The grade of water, on the other hand, varies depending on the end product's requirements. Water may be required for some pharmaceutical medications and medical equipment to meet certain quality standards, while others may have less stringent needs.
Pharmaceutical companies can adopt any of the two means defined by the USP to produce WFI
1. De-chlorination - This is the process of removing chlorine from water. Running water through activated carbon media is one of the procedures for de-chlorination. The carbon combines with the water's free chlorine to produce hydrochloric acid and carbon monoxide/dioxide, effectively dechlorinating it.
2. Using Ion Removal Membrane processes, ion exchange processes, and distillation processes are the three ways used to remove ions. To make WFI, manufacturers use one or a combination of these procedures. The goal of the ion removal procedure is to lower conductivity by removing undesired ions and particles and, if possible, adding some beneficial ions.
There is no specific and accurate calculation for the cost that is required in water plants in food industries. It varies from company to company and quality index is also an important factor in cost. The approximate valuation starts from one lakh up to 2-3 lakhs rupee models.