BP 203 T.

PHARMACEUTICAL
ENGINEERING (Theory)
FILTRATION
MR.YASH MACHHI
ASSITANT PROFESSOR
DEPARTMENT OF PHARMACEUTICAL TECHNOLOGY
FILTRATION – Definition (Pharmaceutical Engineering):
Filtration is a mechanical or physical process used to separate solid particles from a liquid or gas by passing
the mixture through a porous medium (filter), which allows only the fluid to pass while retaining the solids.
It's commonly used in pharmaceuticals to purify solutions, sterilize products, and ensure product quality.
MECHANISM - of Filtration in Pharmaceutical Engineering
Filtration works by passing a fluid (liquid or gas) through a porous filter medium that allows
the fluid to pass while retaining solid particles. The separation can occur by:

1.Mechanical Straining – Particles larger than the pores are physically blocked.
2.Sedimentation – Heavier particles settle into the filter media by gravity.
3.Adsorption – Particles stick to the surface of the filter material.
4.Electrostatic Attraction – Fine particles are trapped due to charge differences.
5.Inertial Impaction – Particles deviate from the fluid path and hit the filter fibers.

These mechanisms can act alone or together depending on the type of filter and the
process.
OBJECTIVES:

1.Remove Particulate Matter: To separate solid impurities (like dust, microorganisms, or undissolved
solids) from liquids or gases.
2.Clarification: To obtain a clear solution free from visible particles.
3.Sterilization: To remove bacteria or microbes using sterile filtration (especially before filling sterile
dosage forms).
4.Product Recovery: To collect valuable solid or liquid from a mixture.
5.Protect Equipment: To prevent clogging or damage to downstream equipment.

APPLICATIONS:

1.Sterile Filtration of Injectables: Removes bacteria before packaging parenteral drugs.

2.Air Filtration in Cleanrooms: Ensures microbial-free air using HEPA filters.
3.Filtration of Culture Media: Removes contaminants in fermentation processes.
4.Solvent and Water Filtration: For purified water systems (WFI) and solvent recovery.
5.Tablet Coating Solutions: Filtration of coating liquids to avoid nozzle clogging.
FACTORS INFLUENCING FILTRATION:
1.Filter Medium:
1. Pore size, material, and thickness affect flow rate and retention efficiency.
2.Viscosity of the Fluid:
1. Higher viscosity slows down filtration rate.
3.Temperature:
1. Higher temperature reduces viscosity, improving flow.
4.Pressure Difference (Driving Force):
1. Increased pressure or vacuum enhances filtration rate.
5.Particle Size and Concentration:
1. Smaller particles may clog the filter; higher solid load can form a thick cake, slowing
filtration.
6.Surface Area of Filter:
1. Larger area allows faster filtration due to more space for fluid to pass.
PLATE AND FRAME FILTER
1. Principle:

Filtration under pressure using a series of alternating plates and frames. Solid particles are
retained on the filter medium, while the liquid passes through.

2. Construction:

•Plates and Frames: Arranged alternately.

•Filter Medium: Placed between plates and frames (e.g., cloth).
•Channels: Allow flow of filtrate and slurry.
•Pump: Feeds the slurry into the system.
•Frame: Holds unfiltered slurry; plate supports filtered liquid.
3. Working:

1.Slurry is pumped into the frames.

2.Liquid passes through the filter medium on the plate.
3.Solids stay in the frame as "cake."
4.Filtrate exits through channels.
5.After filtration, the cake is removed manually.

4. Uses:

•Clarification of liquids.
•Separation of solids from pharmaceutical suspensions.
•Sterile filtration (with proper media).
5. Merits:

•Simple design.
•Easy to operate and clean.
•Provides a large surface area.
•Suitable for batch filtration.

6. Demerits:

•Labor-intensive (manual cake removal).

•Not suitable for continuous operation.
•Time-consuming for cleaning and reassembly.
•Leakage may occur if plates not aligned properly.
FILTER LEAF
1. Principle:

Filtration by suction or pressure through a filter medium attached to a leaf-shaped frame.

2. Construction:

•Leaf: A hollow metal frame covered with filter cloth.

•Outlet pipe: Inside the leaf to carry filtrate.
•Tank: Holds slurry.
•Pump: Moves slurry into the tank.
•Multiple leaves can be used together for larger operations.
3. Working:

1.Slurry is pumped into the tank.

2.Liquid passes through the filter cloth on the leaf.
3.Solids stay on the cloth as a "cake."
4.Filtrate flows out through the leaf outlet.
5.After filtration, the cake is dried and removed.

4. Uses:

•Filtration of large volumes.

•Used in antibiotics, vaccines, and other liquid pharmaceuticals.
5. Merits:

•Large filtration area.

•Easy to remove and dry the cake.
•Continuous or batch operation possible.
•Less space needed than plate and frame filters.

6. Demerits:

•Higher initial cost.

•Cleaning can be tricky.
•Cloth replacement needed regularly
ROTARY DRUM FILTER
1. Principle:

Continuous vacuum filtration – solids are separated from liquid as a rotating drum passes
through slurry.

2. Construction:

•Rotating drum: Half-submerged in slurry tank.

•Filter cloth: Covers the drum surface.
•Vacuum system: Draws liquid through the drum.
•Scraper blade: Removes the solid cake.
•Pipes and valves: Control suction and discharge.
3. Working:

1.Drum rotates slowly in slurry.

2.Vacuum sucks liquid through the filter cloth.
3.Solids form a "cake" on the drum surface.
4.Cake dries as drum rotates.
5.Scraper removes the cake continuously.
6.Filtrate is collected separately.

4. Uses:

•Large-scale filtration of slurries.

•Used in antibiotics, enzymes, and bulk drug production.
5. Merits:

•Continuous operation.
•Saves time and labor.
•Handles large volumes.
•Easy cake removal.

6. Demerits:

•High cost.
•Needs regular maintenance.
•Not suitable for small batches.
•Can clog with fine particles.
META FILTER

1. Principle:
The meta filter works on the surface filtration principle — particles are
trapped on the surface of a filter medium, not inside it.

2. Construction:
•A metal frame supports the filter.
•Filter elements (like mesh, cloth, or cartridges)
are fixed inside.
•Slurry (solid-liquid mixture) enters the filter
housing.
•Filtrate outlet allows clean liquid to pass out.
3. Working:
•Slurry is pumped into the filter.
•Solids stay on the surface of the filter medium, forming a filter
cake.
•Clear liquid (filtrate) passes through and exits.
•Once the cake is thick, it is removed, and the process is repeated.

4. Uses:
•Used in pharmaceuticals, chemical industries,
and food processing to filter liquids and
recover solids.
5. Merits:
•Easy to operate and clean.
•Reusable filter media.
•Efficient for large-scale filtration.

6. Demerits:
•Not suitable for very fine particles.
•Cake removal can be time-consuming.
•Initial cost may be high.
 CARTRIDGE FILTER
1. Principle:
Cartridge filter works on the depth or surface filtration principle — it
removes particles by trapping them in or on the filter material.

2. Construction:
•Made of a cylindrical housing (metal or
plastic).
•Inside is a filter cartridge (made of paper,
fiber, or membrane).
•The cartridge is replaceable and fits tightly in
the housing.
3. Working:
•Liquid enters the filter housing.
•It flows through the cartridge.
•Impurities are trapped, and clean liquid comes out.
•Cartridge is replaced when clogged.

4. Uses:
•Used for water purification, IV fluids, air/gas
filtration, and sterile filtration in pharmaceuticals.
5. Merits:
•Easy to install and replace.
•Compact and efficient.
•Available in different grades (micron sizes).
•Suitable for sterile filtration.

6. Demerits:
•Cartridge needs frequent replacement.
•Not ideal for high solid loads.
•Can be costly over time.
 MEMBRANE FILTERS
1. Principle:
Membrane filters work on the principle of surface filtration — particles larger
than the membrane pores are blocked, allowing only clean liquid or gas to
pass through

2. Construction:
•Made of thin polymer membranes (e.g.,
cellulose acetate, nylon).
•Fixed in a plastic or metal holder.
•Pore sizes range from 0.1 to 0.45 microns
(used for sterilization).
3. Working:
•Liquid or gas is passed through the membrane.
•Microorganisms and particles are retained on the membrane surface.
•The filtrate (clean fluid) passes through.

4. Uses:
•Sterilizing solutions (like IV fluids, vaccines).
•Air and gas filtration in aseptic areas.
•Final filtration before packaging.
5. Merits:
•High filtration precision.
•Ideal for sterile filtration.
•No chemical additives needed.
•Easy to use and install.

6. Demerits:
•Can clog quickly if solution has many particles.
•Not suitable for filtering large volumes with high solid content.
•Fragile; needs careful handling.
SEIDTZ FILTER
1. Principle:
Seitz filter works on the principle of depth filtration — particles are trapped
within the thickness of the filter pad, not just on the surface.

2. Construction:
•Made of a metal frame that holds filter pads.
•The filter pads are made of asbestos or
cellulose fibers.
•Pads are placed between support plates with
openings for liquid flow.
3. Working:
•Liquid is passed under pressure through the filter pads.
•Suspended particles and microbes get trapped inside the pad layers.
•The clear filtrate comes out from the other side.

4. Uses:
•Used for sterile filtration of heat-sensitive solutions.
•Common in vaccine, serum, and antibiotic production.
5. Merits:
•Good for clarification and sterilization.
•Handles large volumes.
•Pads are easy to replace.

6. Demerits:
•Pads can shed fibers (may need further filtration).
•Not suitable for very fine sterilization without pad treatment.
•Asbestos pads (older type) are hazardous and rarely used now.
 PERFORATED BASKET CENTRIFUGE

1. Principles
•Works on centrifugal force.
•When the basket rotates at high speed, it throws out the liquid, and solids are retained inside the
perforated basket.

2. Construction
•Cylindrical perforated basket: Holds the slurry (solid + liquid).
•Outer casing: Collects the separated liquid.
•Motor: Rotates the basket.
•Brake and drive system: Controls the speed.
•Filter cloth: Lines the inside of the basket to prevent solid loss.
3. Working
1.Slurry is fed into the basket.
2.Basket spins at high speed.
3.Liquid passes through perforations and is collected outside.
4.Solids stay inside the basket.
5.Solids are then manually or mechanically removed.

4. Uses
•Used for solid-liquid separation in:
• Pharmaceuticals
• Chemicals
• Food processing
• Dye and textile industries
5. Merits
•Simple operation
•Efficient solid-liquid separation
•High-speed processing
•Low maintenance

6. Demerits
•Not suitable for fine particles (can clog)
•Batch process (not continuous)
•Manual removal of solids can be labor-intensive
NON-PERFORATED BASKET CENTRIFUGE

1. Principle
•Works on centrifugal force.
•Unlike the perforated type, the basket has no holes, so separation happens by settling due to rotation.

2. Construction
•Solid (non-perforated) basket: No holes; holds slurry.
•Outer casing: Contains any splashes.
•Motor: Spins the basket.
•Cover/lid: For safety.
•Inlet and outlet: For feeding and draining liquids.
3. Working
1.Slurry is fed into the solid basket.
2.Basket rotates at high speed.
3.Heavier solids settle at the bottom and sides.
4.Liquid remains at the top and is decanted or drained out later.
5.Solids are manually removed.

4. Uses
•Used when:
• Fine particles are present
• Need gentle handling
• Filtration is not needed
5. Merits
•Suitable for fine or sticky materials
•No clogging (no perforations)
•Gentle processing

6. Demerits
•Slower separation
•Less efficient than perforated type
•Needs manual removal of both liquid and solids
SEMI-CONTINUOUS CENTRIFUGE
1. Principle
•Works on centrifugal force.
•Separates solid and liquid by spinning the mixture.
•Operates in semi-continuous mode — feeding is continuous, but discharge is intermittent.

2. Construction
•Cylindrical basket (with or without perforations)
•Filter cloth: Holds back solids
•Feeding pipe: For continuous slurry input
•Discharge system: Removes solids at intervals (e.g. scraper)
•Motor & drive system: Spins the basket
3. Working
1.Slurry is continuously fed into the spinning basket.
2.Liquid is separated and drained.
3.Solids collect inside the basket.
4.After a certain time, solids are discharged manually or by a scraper.
5.Cycle repeats.

4. Uses
•Ideal for medium-scale production
•Used in pharmaceuticals, chemicals, and food industry
5. Merits
•Faster than batch centrifuges
•Lower labor requirement
•Suitable for sticky or fine solids

6. Demerits
•Not fully automatic
•Needs monitoring
•Limited capacity compared to fully continuous centrifuges
SUPER CENTRIFUGE
1. Principle
•Works on very high-speed centrifugal force (up to 20,000 rpm).
•Separates liquids of different densities or liquid-solid mixtures.
•Based on density difference.

2. Construction
•Long, vertical, rotating bowl
•No perforations
•Inlet at the bottom for feeding liquid
•Outlet at different levels for separated layers
•Motor for high-speed rotation
•Often enclosed for safety due to high speed
3. Working
1.Feed is introduced into the spinning bowl.
2.Due to high centrifugal force:
1. Heavier phase (solid or denser liquid) moves outward
2. Lighter phase stays near the center
3.Separated layers are removed through different outlets.

4. Uses
•Used to separate:
• Two immiscible liquids
• Fine solids from liquids
•Applications in:
• Pharmaceuticals
• Oil-water separation
• Blood plasma separation
5. Merits
•Very efficient separation
•Works well for fine particles and emulsions
•Continuous operation

6. Demerits
•Expensive
•High energy consumption
•Needs skilled operation and maintenance