Pharmaceutical Technologist - July 2008 - (Page 22)

Reducing waste water is a process central to the company’s manufacturing operation, as well as the most water-intensive. The second stage of the washing process alone utilized 1500 L/h — 10 times the amount the average person uses in one day. The product had to pass through a number of washes, and the company found that by recycling water from the final rinse for reuse in the first stage of a different wash, significant amounts could be saved. Through the process of measuring and monitoring, the company also identified a leak in the boiler plant heat exchanger. Automated continuous monitoring equipment was also installed and procedures for water supply shut-off were improved. Recently, the company has invested in new technology to recycle treated effluent, which will add even more savings. Where to look One area that should not be overlooked by companies is ‘domestic’ usage. Domestic use in the pharmaceutical sector is significantly less than main process use, but it is not negligible. By installing simple low-cost water saving devices, such as water-efficient toilets, showers and taps, sites can achieve a 40% reduction in consumption. Vessel washing is also a major area of water use for the sector and companies that address this area can achieve significant cost savings. Below are a number of procedural issues that could help reduce wastage and cut costs: ● Batch formulation — review and, if possible, alter procedures to reduce water waste. Instruction cards — develop washing instruction/procedure cards to inform staff of the most effective washing methods. ● Mixing outside the vessel — this may reduce the need for vessel washing. ● Equipment dedication — where possible, dedicate mixing vessels to specific products so less cleaning is required. ● Some products may be compatible and stringent washing down between batch operations may not be required. Using the same base chemical for products increases compatibility. ● Production scheduling — plan the sequence of production batches so that compatible products follow each other, minimizing the need for washing. ● Vessel washing matrix — identify the levels of cleanliness between different products and devise the optimum washing requirements between product batches. ● Selection of solvent/cleaning agent — use different solvents/cleaning agents for different stages in the vessel wash in cases where this enables reduced overall use and does not compromise wash liquor re-use. ● Material recovery — use membrane systems to recover high-value products/materials from effluent. ● Inspection and monitoring — sample rinse water during a new or trial wash cycle to establish when a vessel is clean. Given that the costs both to buy water and to dispose of it are ● constantly increasing, it makes good business sense to use this valuable resource more efficiently. Identifying and understanding the causes of wastage, and a company wide commitment to reduce water use is the key to achieving this. PT Envirowise Envirowise is a UK government-funded programme that provides UK companies with free sector-specific advice and practical guidance on all areas of resource efficiency. Envirowise will be rolling out a new water efficiency initiative called the Rippleffect to help companies save money. Visit the Envirowise website to find out more and access a range of free information and tools (www.envirowise.gov.uk/water). Further information on the eight-step water minimization plan and a cost savings worksheet is included in ‘Managing Water Use in Speciality Chemicals Manufacture: A Signposting Guide’, which is available to order or download free-of-charge at www.envirowise.gov.uk/GG363. 22 JULY 2008 PHARMACEUTICAL TECHNOLOGIST http://www.envirowise.gov.uk/water http://www.envirowise.gov.uk/GG363

Table of Contents Feed for the Digital Edition of Pharmaceutical Technologist - July 2008

Pharmaceutical Technologist - July 2008 Contents Industry Highlights Morpheus Market Watch Overcoming the Barriers The Tide of Change Eight Steps to Improved Water Efficiency Q&A

Pharmaceutical Technologist - July 2008

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