Pall Corporation (PLL): Filtration, Separations, Purification & Environmental Technology
Home
1.800.717.7255 (USA)EMAIL USCONTACT US

Pall Activated Carbon Filters Incorporating Seitz® AKS Filter Media

Pall Activated Carbon Filters Incorporating Seitz® AKS Filter Media
INQUIRE NOW

Streamlining Your Process
with Pall Carbon Filters

Powdered Activated Carbon (PAC) is widely used in the pharmaceutical industry for decolorization and removal of other trace impurities. The use of bulk PAC has significant drawbacks relating to the handling of bulk carbon powder, cleaning of process equipment, and time (costs) associated with carbon removal from the process. Seitz® AKS immobilized carbon filter media alleviates these concerns by incorporating activated carbon within a matrix of cellulosic fibers. This immobilized carbon media is then coupled with a downstream filter paper that eliminates any possible carbon particle shedding downstream of the filter.  Additionally, the adsorption efficiency of Seitz AKS immobilized carbon filter media is greater than an equivalent amount of bulk PAC, further reducing overall  process time and increasing product yield.

Now available in Stax Disposable Capsule Format!

Pharmaceutical processes involving the addition of Bulk Activated Carbon, generally involve 4 operations:

  1. Handling of bulk carbon and dosing into a mixing vessel
    This can result in the distribution of carbon dust into the working environment, with potentially detrimental effects on both occupational hygiene and good manufacturing practice.
  2. Mixing of bulk carbon with product solution
    This involves agitation for sufficient time to allow the majority of the impurity molecules to come into contact with the PAC, diffuse into the internal structure of the carbon particles, and be adsorbed onto the internal surface of the carbon. This operation typically lasts at least 30 minutes.
  3. Removal of PAC from the process after adsorption
    Bulk carbon is usually removed by a cake filtration process, whereby the suspension is recirculated over a filter sheet or cloth supported by a porous plate. Particles build up on the surface of the filter forming a “cake”, which also contributes to the filtration process. Additional “polishing” filtration steps with cartridge filters are  typically required to remove carbon fines and provide a clear fluid for the subsequent step.
  4. Cleaning of carbon from process equipment
    Carbon powder can become widely distributed through process equipment and can be very difficult to completely remove. This is particularly problematic for pilot plants and multipurpose plants where cleaning of process equipment between batches is a critical issue to avoid cross-contamination.

Figure 1: A typical decolorization process involving addition of bulk activated carbon (cleaning steps not shown)

 

Figure 2: A typical decolorization process using a Seitz AKS immobilized activated carbon filter media assembly

Seitz AKS Filter Media - The Better Choice

Pall Seitz AKS immobilized carbon filter media provides a streamlined process only requiring a single step. The feed stream is simply passed once through the module at an appropriate flow rate to achieve the desired adsorption. This saves time, resources, and expense. It is nearly 100% free of carbon dust so operators and the workspace are much better protected. No additional mixing, filtration, or cleaning steps are needed.

Improved Adsorption

In addition to streamlining the process, Pall Seitz AKS immobilized carbon filters are actually more efficient at removing colors and other impurities from a solution compared to a batch process with the equivalent PAC grade (Figure 3).



There are two reasons for the improved efficiency of sheet-based adsorption compared to bulk mixing adsorption processes.

  1. At an optimized flow rate, the probability of contact between the impurities and carbon particles is greater in carbon-impregnated sheets. This is due to process fluids
    more efficiently contacting carbon particles immobilized into a sheet matrix.
  2. Due to the depth (thickness) of the sheet, it is possible to consider the structure as being made up of a series of layers containing PAC. The initial layers make first
    contact with the fluid and as time and increasing fluid volume is passed through this layer they are the first to become saturated with impurity. Subsequent layers, however, still have adsorbing sites and a capacity to adsorb impurity, which increases through the depth of the media (figure 4). In essence, having a depth of PAC and
    passing the fluid at an optimal flow rate through that depth enables the potential of the carbon to adsorb impurity to be fully utilized.

Ensuring Highly Efficient Contaminant Removal

Pall offers a complete range of UpScaleSM program products available with all 9 different AKS media grades suitable for the development laboratory through the pilot plant to full production. Media test discs are available as 47 mm, 60 mm and 90 mm diameter discs (other sizes upon request). Also available are highly convenient, fully disposable Supracap 60 capsules (26 cm2) for grade section and process development.

For pilot plant or small production, Supra AKS cartidges may be used. Supra AKS depth filter cartridges are available in 10 in., 20 in. and 30 in. size with all AKS grades. Supra AKS cartridges follow the same design principle as Supracap 100 capsule internal elements and consist of activated carbon depth filter sheets supported by inside and outside separators. The entire element is held together by 4 support jackets as well as an inner support anchor. Supra AKS cartridges feature a code 7 adapter for ease of use in standard stainless steel cartridge housings.

For For full scale production Supradisc™ AKS modules (12 in. or 16 in.), Supracap 200 depth filter capsules and Stax disposable capsules are available.

Supracap 200 filters are fully encapsulated Supradisc modules, designed for applications with hazardous materials. The encapsulation of the module significantly reduces operator exposure and simplifies handling during change-out. Furthermore, the encapsulated modules provide a dramatic reduction in the proportion of normally wetted surfaces in the housing, resulting in faster hardware clean-up and easier cleaning  validation compared to standard lenticular formats. For detailed information regarding Supracap 200 capsules please refer to the relevant web page or contact Pall.

The Stax disposable capsule format with Seitz AKS media provides a ready-to-use, easy to handle system. Scalable in size and performance to meet lab, pilot and process needs, the Stax AKS capsules are ideal for use in applications from 50 – 20,000+ L.

For selection and optimization studies, we recommend performing adsorption evaluation studies at a recommended range of flow rates either at your facility or in our Scientific and  Laboratory Services (SLS) laboratories using the appropriate UpScale program product with Seitz AKS media. Pall specialists can provide valuable expertise, providing hands-on assistance if  required and placing our extensive technical resources at your disposal.