How to calculate the hourly compressed air consumption of the equipment

In the production of sterile drugs, should choose full oil-free air compressor especially through ISO 8573-1 Class 0 certification models, such as oil-free scroll air compressors or water-lubricated oil-free screw air compressors. The following is a detailed analysis of this choice:

core Requirements for Air Compressor in 1. Sterile Pharmaceutical Production

1. air purity
   • sterile pharmaceutical production must be strictly followed GMP (Good Manufacturing Practice) the compressed air must reach no dust, no oil, no moisture of standards.
   • Oil, particles or microorganisms in the air may contaminate medicines, leading to quality defects and even threatening patient safety. For example, oil residues may lead to the disposal of pharmaceutical batches, and microbial contamination may pose a risk of infection.
2. Reliability
   • air compressors need to run continuously for a long time, and unstable gas source pressure may lead to production interruption, affecting efficiency and product quality.
   • High reliability is required to reduce unplanned downtime, for example, through dual system redundancy design (such as dual motors, dual main engine) to ensure uninterrupted gas supply.
3. Environmental protection and energy efficiency
   • need to choose high energy efficiency grade equipment, reduce power consumption.
   • Frequency conversion technology is adopted to adjust the output according to the actual gas consumption to reduce energy consumption.
   • The equipment should be low noise, low vibration, reduce the impact on the environment.

Technical Advantages of 2. Oil-free Air Compressor

1. no risk of oil contamination
   • full oil-free air compressor(such as water lubricated oil-free screw air compressor) in the compression process does not use lubricating oil, from the source to prevent oil pollution.
   • collocation three-stage precision filtration + adsorption dryer, can achieve:
     • oil content ≤ 0.001ppm (far below industry requirements);
     • dew point ≤ -45 ℃ (to meet the stringent requirements for dryness of sterile drugs);
     • solid particle accuracy ≤ 0.01 μm (to prevent microbial growth).
2. Material Compliance
   • parts in contact with compressed air (such as pipelines and air storage tanks) shall be used. 316L stainless steel(Better than 304 stainless steel commonly used in the medical industry), corrosion resistance and no metal ion precipitation.
   • The whole machine needs to pass ISO 13485 medical equipment quality management system certification and with cleanliness test report.
3. Operation stability
   • equipped with intelligent control system, real-time monitoring and adjustment of operating parameters to maintain stable output.
   • Use durable materials (such as corrosion-resistant and wear-resistant parts) to reduce maintenance frequency.
   • Configure standby units to deal with sudden failures and ensure continuous production.

3. recommended models: oil-free scroll air compressor and water-lubricated oil-free screw air compressor

1. oil-free Scroll Air Compressor
   • advantage: Novel structure, small size, light weight, low noise, long life, stable and continuous gas transmission, easy operation, and low maintenance cost.
   • Applicable Scenarios: medium and small gas volume (≤ 10m & sup3;/min), medium and low pressure (≤ 1.0MPa) sterile drug production, such as liquid preparation filling, solid preparation granulation, etc.
2. Water-lubricated oil-free screw air compressor
   • advantage pure water as lubricating medium, completely eliminate oil pollution; with efficient filtration and drying system, to meet the requirements of high cleanliness.
   • Applicable Scenarios: atmospheric volume (≥ 10m & sup3;/min), high pressure (≥ 1.0MPa) sterile drug production, such as high pressure spraying, large extraction tanks, etc.

4. practical application cases

• A Jiangsu pharmaceutical company: After using water-lubricated oil-free screw air compressor, the qualified rate of drug filling link increased from 98.5 to 99.9, and there was no batch scrapping caused by gas source oil.
• Operating room of a tertiary hospital: The oil-free air compressor with dual-system redundancy design has been running continuously for 3 years without unplanned downtime, meeting the high reliability requirements of surgical gas.

5. selection considerations

1. certification and Standards: Preference to Passed ISO 8573-1 Class 0, GMP, HACCP and FDA certified models.
2. Post-processing system: According to the needs of the configuration of refrigeration dryer, adsorption dryer, precision filter, etc., to ensure that the air quality standards.
3. Maintenance and Cost: Considering the convenience of equipment maintenance and long-term operating costs, priority is given to domestic cost-effective models (such as Sa Zhen and other brands), the price is usually 50%-70% of imported models, and spare parts replacement cycle is short, maintenance response is fast.