Centrifuge Optimization Boosts Output 25%

The industrial centrifuge is a common solid-liquid separation (SLS) device in many pharmaceutical and chemical manufacturing operations. The SLS centrifuge is after all just a cake filter that uses the ‘cake’ (as the deposited solids on the filter media are called) as the basis for further filtration of the solid particles and efficient ‘cake washing’, if needed. The filtering efficiency of the centrifuge depends upon several factors including machine variables, such as G-forces during the various stages of a cycle (more on this in a later blog) and filter media (material, construction, porosity, among others) and process parameters such as solids size, shape and concentration, their settling and filtering characteristics under high Gs, the cake characteristic, among several other variables.

A recent centrifuge optimization project at a leading US-based multinational pharmaceutical company has resulted in a 25% increase in production. Optimization of three batch-operated vertical basket filtration type Centrifuges has also provided operational and other cost saving benefits upstream and downstream of the centrifuge operation.

Existing Problem – The company had to meet a significant increase in demand for its products without investing in additional plant and equipment. The solution therefore was to optimize its existing centrifuge filtration process by looking to reduce batch times, thus increasing product throughput. The process centred around three vertical batch basket filtration centrifuges, capable of recovering upto 1200 kg/hr final cake solids. To achieve this level of throughput it was necessary to both reduce the process cycles times and increase the payload of retained product solids in each basket load.

Solution – Acting as the independent consultants on the project we initially carried out a detailed Site Survey, submitting proposals for a comprehensive process optimisation package. Operator Training was particularly important in the revised process requirements and providing the operators with knowledge of centrifuge controls, capabilities and limitations and the need to maintain strict health and safety requirements.

Key Benefits – Cost savings were also identified through using less product wash liquids leading to a corresponding reduction in effluent discharge levels hence reducing operating costs. It was also possible to operate each centrifuge continuously for much longer periods before having to remove the ‘heel’ and clean its internal surfaces. From a Health & Safety perspective, the improved operation of the process has reduced the frequency of basket inspections and cleaning operations by 50%.

According to site management the end result of the centrifuge optimization project has seen a 25% increase in production which will help satisfy current escalating demand from their clients around the world. As a general spin-off from our involvement they now have an industrial centrifuge filtration process that requires less maintenance, is more environmentally friendly and provides healthier working conditions for company site teams.

In future blogs, we will explore how each of the various machine and process parameters play an important role in optimizing your centrifuge capacity. So, stay tuned and check back often.

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