Improving processes for pharma manufacturing giant with custom housings

The problem

A multinational pharmaceutical and biotechnology corporation required assistance with the design and build of 100 filter housings capable of handling both gas and liquid in 316L Stainless Steel and Hastelloy (C22). The materials had to be matched to the solvents and gases being processed to ensure compatibility.

Manufacturing sensitive final API solutions requires a combination of aggressive starter chemicals. Our client had specific design requirements for their filter housings to ensure the health and safety of their operators and to optimise the process design. 

This was outside the capabilities of other housing manufacturers because they could only supply standard, 'off-the-shelf' designs.

Large manufacturing projects are usually handled by global engineering contractors. They may have overall responsibility for the design and delivery of the turnkey installation but filtration is only a small, although critical, part of the process. The contractor must work with a highly knowledgeable filter manufacturer. This is because they have the expertise to identify potential issues and recommend improved designs. Basic specification sheets, often supplied by contractors, aren't enough to supply the most appropriate product. 

The supply chain consisted of an Asian contracting company, who dealt with their European operator, who dealt with a distributor, who then dealt with Amazon Filters. This structure required clear and concise communication and a knowledgeable distribution partner with expertise in pharmaceutical applications. For example, a filtration designer who could talk directly with the client’s engineers.

Requirements

1. Design custom housings suitable for their process
2. Meet the strict health and safety requirements of pharma processing
3. Delivered by one housings manufacturer in-house, without the need to subcontract out