Pharmaceutical

The pharmaceutical industry operates in an environment with strict requirements on safety, sterility and accuracy. In the manufacture of pharmaceutical products, medicaments and high-purity water – IPTech sensors are reliable and easy to clean.

Applications

Bioreactor

Level and pressure measurement in the production of enzymes, proteins and antibodies

Application

Some pharmaceutical companies use bioreactor vessels to cultivate particular cells or microorganisms required for certain treatments. The very high level of hygiene required means the vessels and all associated parts must be easy to thoroughly clean, because even the slightest contamination with other organisms can lead to an aborted production run. These reactors are mainly “batch-fed”, where they are completely filled at the start and not emptied again until the process is completed. The pressure and level in the reactor have to be monitored continuously during process in order to obtain a high-quality yield.

Your benefit

Reliable
Unaffected by extreme process conditions
Cost effective
Reliable, continuous operation with absolute hygiene
User friendly
Easy adjustment and setup, as internals do not interfere

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Reactor
Measuring range up to:
5 m
Medium:
Microorganisms
Process temperature:
+20 … +80 °C
Process pressure:
-1 … +5 bar
Special challenges:
Frequent cleaning cycles

Filter system

Differential pressure measurement for filter monitoring

Application

Often, in the manufacture of pharmaceuticals, substances need to be separated from one another or perhaps some cell components precipitated. One method of doing this is using special filtration systems. When the filter is working properly, the quality and yield of the products are at their optimum. So continuous differential pressure monitoring of the filters ensures the filters are running at their most efficient at all times.

Your benefit

Reliable
Self-monitoring ceramic measuring cell with 3A/EHEDG approval
Cost effective
Efficient operation and cleaning of the filter during continuous operation
User friendly
One measuring system, three measurements: differential pressure, static pressure, temperature

Process data

Measuring task:
Differential pressure measurement
Measuring point:
Pipe
Measuring range up to:
5 m
Medium:
Water
Process temperature:
0 … +50 °C
Process pressure:
0 … +5 bar
Special challenges:
Fast response times of the measurement

Ultrapure water storage tank

Level and pressure measurement in storage tanks for ultrapure water (Water for Injections)

Application

High-purity water (WFI) is required for pharmaceutical products that are injected directly into the bloodstream or administered as eye or nose drops. This water is produced through filtration and distillation, then stored temporarily in tanks. Absolute sterility and cleanability are essential criteria for all process components that have direct contact with the medium. This also applies to the instruments for level and pressure measurement in the tank.

Your benefit

Reliable
Certified hygienic design (3A/EHEDG) and approved materials according to EC 1935/2004 and FDA
Cost effective
Three instruments deliver four different measured values: pressure (head pressure and line pressure), liquid level and temperature
User friendly
Standardized housing and adjustment concept

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Tank and pipeline
Measuring range up to:
5 m
Medium:
water
Process temperature:
-40 … +135 °C
Process pressure:
0 … +5 bar
Special challenges:
Hygienic production conditions

Storage tanks for liquids

Liquid level measurement and switching in storage tanks for finished products

Application

Many different liquids with widely varying properties are required in pharmaceutical production. Products, at all stages have to be stored and held ready for subsequent processing. These are used as catalysts for the decomposition of compounds and stored in a wide variety of concentrations, some of these products are acids. For smooth production and optimal storage, reliable level measurement and point level detection are absolutely necessary.

Your benefit

Reliable
Point level detection with WHG
Cost effective
Excellent material and process compatibility ensures long service life and uninterrupted operation
User friendly
Standardized housing and adjustment concept

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
10 m
Medium:
Liquids with very different properties
Process temperature:
+20 … +35 °C
Process pressure:
0 … +35 bar
Special challenges:
Changing, aggressive and corrosive liquids

Reaction vessel

Level and pressure measurement and point level detection in multi-product and multi-line production facilities

Application

The measuring conditions inside a reaction vessel in a multi-product, multi-line production facility are characterized by changing media as well as widely fluctuating temperatures and pressures. Depending on the properties of the raw materials, either alloy, stainless steel or enamel lined vessels are used. Different components like stirrers, dryers and centrifuges also vary in each process. To ensure reliable operation and high productivity, both level and pressure have to be continuously measured and monitored.

Your benefit

Reliable
Certified hygienic design (3A/EHEDG) and approved materials according to EC 1935/2004 and FDA
Cost effective
Three instruments deliver four different measured values: pressure (head pressure and line pressure), level and temperature
User friendly
Standardized adjustment, process data storable and transferable

Process data

Measuring task:
Level and pressure measurement, point level detection
Measuring point:
Reactor
Measuring range up to:
5 m
Medium:
Raw materials and mixed products
Process temperature:
+20 … +200° C
Process pressure:
-1 … +5 bar
Special challenges:
High temperatures, internal tank installations, changing media, Condensate

Reaction vessel with solvents

Level and pressure measurement and point level detection in mixing processes

Application

The key component in the manufacture of pharmaceutical products is the reactor. Different raw materials are mixed with solvents and made to react by applying heat and pressure. During this process, the pressure, temperature and consistency of the medium are changing constantly. A stirrer ensures homogeneous mixing of the product, and can also cause an agitated surface and heavy foaming. To ensure a reliable process, the liquid level in the reaction vessel must be reliably and continuously monitored.

Your benefit

Reliable
Certified materials in compliance with FDA and EC 1935/2004
Cost effective
Three instruments, four measured values: Pressure, level, temperature and point level
User friendly
Low installation expenditure

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Reactor
Measuring range up to:
3 m
Medium:
Pharmaceutical raw materials and mixed products
Process temperature:
-20 … +120 °C
Process pressure:
-1 … +10 bar
Special challenges:
Internal tank fixtures

Batching tank for ointments

Level and pressure measurement and point level detection in ointment production in batch mode

Application

Many different ointments and creams are produced in batching tanks. The process conditions in batch production are typically characterized by high temperatures and vacuum. After each batch run, the tank needs to be cleaned quickly and effectively with chemically aggressive cleaning agents ready for the next batch. Contamination of the products during the mixing or reaction process is prevented by the use of a protective gas atmosphere. To ensure a safe, reliable process, both the level and the gas head pressure must be continuously monitored.

Your benefit

Reliable
Certified materials in compliance with FDA and EC 1935/2004
Cost effective
Maintenance-free operation
User friendly
Easy installation

Process data

Measuring task:
Level and pressure measurement, point level detection
Measuring point:
Reactor
Measuring range up to:
10 m
Medium:
Ointments and creams
Process temperature:
+20 … +135 °C
Process pressure:
-1 … +5 bar
Special challenges:
Frequent, extreme temperature changes in batch mode (cleaning), tank internal structures and mixers

Fluidized bed reactor

Level measurement and filter monitoring in granulate production in the fluidized bed process

Application

One method for producing and drying granulates is the fluidized bed process. A uniform stream of air is fed up through a distributor plate at the bottom of the fluidized bed reactor. A liquid granule suspension is sprayed in from above, in the air stream it turns into solid granulate and collects on the top of distributor plate and the exhaust air flows through a filter for cleaning. To ensure a high-quality process, both the granulate quantity on the distributor plate and the condition of the filter must be permanently monitored. The measurement technology must also fulfil the most stringent hygienic requirements in order to guarantee a consistently high granulate quality.

Your benefit

Reliable
Certified hygienic design (3A/EHEDG) and approved materials according to EC 1935/2004 and FDA
Cost effective
Three instruments, four measured values: pressure (vessel and line), granulate level and temperature
User friendly
Process data storable and transferable

Process data

Measuring task:
Level measurement and filter monitoring
Measuring point:
Reactor
Measuring range up to:
10 m
Medium:
Water and granulate
Process temperature:
+20…+150° C
Process pressure:
-1 … +10 bar
Special challenges:
Abrasive media

Batch holding tank on a filling system

Level measurement in the holding tank of a filling system

Application

Pharmaceutical products such as drugs and vaccines are held in batch filling holding tanks ready to be filled into injection vials under absolutely sterile conditions. After each batch, the holding tank has to be totally sterilized using an autoclaving procedure. During this process, the sensor is exposed to a pressure of 2.5 bar and a temperature of 130 °C for at least half an hour. The rapidly changing levels of the aqueous liquids are continuously monitored. The rapidly changing levels of the aqueous liquids require continuous and precise monitoring.

Your benefit

Reliable
Approved materials in compliance with FDA and EC 1935/2004
Cost effective
Reliable, continuous operation with absolute hygiene
User friendly
Standardized housing and adjustment concept

Process data

Measuring task:
Level measurement
Measuring point:
Tank
Measuring range up to:
0.3 m
Medium:
Conductive solution
Process temperature:
+20 … +50 °C
Process pressure:
0 … +15 bar
Special challenges:
Small levels, rapid level changes, Autoclaving

Liquid waste buffer tank

Level measurement and point level detection in buffer tanks for liquid waste

Application

In preparation for proper disposal, liquid wastes that arise in the production of pharmaceuticals are temporarily stored in buffer tanks. These potentially hazardous mixtures consist of diverse media with very different properties including dielectric conductivity (dielectric constant) and density. For optimal storage, reliable and accurate level measurement is required. Point level detection ensures overfill and dry run protection.

Your benefit

Reliable
Dependable protection against overfilling
Cost effective
Optimal utilization of the container volume
User friendly
Simple setup and commissioning

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
8 m
Medium:
Acids and alkalis
Process temperature:
+10 … +30 °C
Process pressure:
0 … +16 bar
Special challenges:
Frequently changing media, media with different dielectric constants

CIP system - cleaning agent storage tanks

Level measurement and point level detection in the cleaning agent storage tank of the CIP system

Application

In the pharmaceutical industry, cleaning of process equipment takes place within the framework of a validated “Clean in Place (CIP)” process to ensure aseptic conditions are maintained in production equipment, tanks and pipelines. Sodium hydroxide or concentrated acids are frequently used as cleaning agents, which are held in storage tanks within the CIP system. They are diluted in a premix vessel prior to use. Level measurement enables safe storage and optimal usage of these cleaning agents. Point level detection serves as overfill and dry run protection.

Your benefit

Reliable
Approved materials in compliance with FDA and EC 1935/2004
Cost effective
Maintenance-free operation
User friendly
Simple mounting

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
3 m
Medium:
Sodium hydroxide/acid
Process temperature:
+5 … +30 °C
Process pressure:
0 … +1 bar
Special challenges:
Chemically aggressive medium

Autoclave

Level and pressure measurement in the autoclave

Application

In the production of medical consumables, autoclaves are commonly used for sterilization. Every autoclave has 4 chambers where medical products are sterilized. They work with dry, saturated steam at 2.7 bar pressure and 130 °C. To regulate the water level in the condensate sump, a reliable level measurement is required. The overpressure is also measured to ensure an optimal and safe autoclaving process.

Your benefit

Reliable
Certified hygienic design (3A/EHEDG) and approved materials in accordance with FDA and EC 1935/2004
Cost effective
Simple stocking: electronics universally applicable
User friendly
Standardized adjustment of all instruments thanks to plics® concept

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Autoclave
Measuring range up to:
0.4 m
Medium:
Water
Process temperature:
+120 …+140 °C
Process pressure:
+1 …+3 bar
Special challenges:
Pressure, temperature, saturated steam, condensation

Hexane storage tank

Level measurement and point level detection in hexane storage tank

Application

In pharmaceutical production, Hexane is a commonly used solvent and reaction medium, as well as an agent for oil and grease extraction. This colourless liquid has a slight petrol odour and is highly volatile light hydrocarbon, readily forming highly flammable vapour-air mixtures. When the tank is emptied, no residues may remain inside. Reliable level measurement and overfill protection is an absolute necessity for safe storage and handling.

Your benefit

Reliable
Approved materials in compliance with FDA and EC 1935/2004
Cost effective
Simple, fast setup
User friendly
Simple mounting

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
15 m
Medium:
n-Hexane
Process temperature:
-40 … +50 °C
Process pressure:
0 … +6 bar
Special challenges:
Media with low dielectric constant

Mixing Vessel

Level measurement in the mixing vessel and pressure measurement in the supply line

Application

Mixing vessels are applied for preparation, storage and transfer of a wide range of pharmaceutical products. These vessels are used for the manufacture of antibiotics, blood plasma products, and injection and infusion solutions. Following preparation, substances are transferred to a filling station. To ensure a reliable process, the liquid level in the mixing vessel must be reliably and continuously monitored.

Your benefit

Reliable
Certified hygienic design (3A/EHEDG) and approved materials according to EC 1935/2004 and FDA
Cost effective
Continuous operation with absolute hygiene
User friendly
Standardized adjustment, process data storable and transferable

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Vessel
Measuring range up to:
1.2 m
Medium:
Antibiotics, injection and infusion solutions, blood plasma products
Process temperature:
+50 … +150 °C
Process pressure:
-1 … +6 bar
Special challenges:
Changing product density, frequent cleaning cycles, small vessels

Preparation tank for solvents

Level measurement in the preparation tank for solvents

Application

The various solvents and intermediate carrier materials have to be first prepared before they proceed onto further production steps. This is usually carried out in bioreactors and fermentation tanks. These vessels are enclosed with a steam heating jacket to regulate the temperature inside the mixing process. The level measuring system is needed to control filling and discharge as well as monitor during the process. Level detection prevents the tank from overfilling or running empty.

Your benefit

Reliable
Approved materials in compliance with FDA and EC 1935/2004
Cost effective
Maintenance-free operation
User friendly
Simple installation

Process data

Measuring task:
Level and pressure measurement, point level detection
Measuring point:
Tank
Measuring range up to:
1.4 m
Medium:
Solvents
Process temperature:
-10 … +150 °C
Process pressure:
-1 … +10 bar
Special challenges:
Condensation, media with low dielectric constant

Vacuum evaporator with scraper system

Level measurement in a vacuum evaporator with scraper system and pressure monitoring in the supply line

Application

A thickening vessel fitted with a scraper is used to increase the concentration of extracted solutions by means of evaporation under vacuum. Extremely precise level measurement is required in this process because the concentration is determined by the filling height. The evaporation system operates according to meeting specified levels. As soon as they reach the correct value, the evaporation process is stopped and the concentrated solution is discharged out of the tank.

Your benefit

Reliable
Optimal concentration thanks to highly accurate level measurement
Cost effective
Easy cleaning without dismantling
User friendly
Simple installation and setup

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Tank
Measuring range up to:
1.6 m
Medium:
Extracted solution
Process temperature:
+50 … +80 °C
Process pressure:
-0.7 … -0.5 bar
Special challenges:
Vacuum, buildup, condensation, vessel internals

Distillation vessel

Level measurement in a distillation vessel and pressure monitoring in the supply line

Application
Solvents are used in the pharmaceutical industry for extracting active ingredients. They are then recovered via evaporation in a high-vacuum distillation vessel. After the solvent has been removed from the pharmaceutical product by evaporation, it is further processed. Reliable level measurement is required in the distillation vessel for process control.
Your benefit
Reliable
Optimised distillation process through a reliable measurement
Cost effective
Simple installation saves time and costs
User friendly
Output of additional measured values

Process data

Measuring task:
Level and pressure measurement
Measuring point:
Tank
Measuring range up to:
3 m
Medium:
Solvent/water mixture
Process temperature:
+40 … +60 °C
Process pressure:
-1 … +3 bar
Special challenges:
Foam

Disposable plastic container

Level measurement in disposable plastic containers

Application

When very small product batches are produced in the pharmaceutical industry, disposable plastic containers are often used. These are essentially polymer bags in which a fermentation process takes place or which contain a certain medium or buffer. Continuous level measurement is required to ensure high process efficiency.

Your benefit

Reliable
Safe, reliable measurement from the outside through the bag
Cost effective
Time and cost-intensive CIP/SIP cleaning no longer required
User friendly
Simple integration and setup

Process data

Measuring task:
Level measurement
Measuring point:
Disposable plastic container
Measuring range up to:
2 m
Medium:
Media for fermentation
Process temperature:
0 … +20 °C
Process pressure:
0 … +0.2 bar
Special challenges:
Measurement through a disposable container, strong condensation of the medium on the inside of the disposable container

Transport containers for liquids

Level measurement of liquids in transport containers

Application

In many of the production processes in the pharmaceutical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.

Your benefit

Reliable
Accurate measurement down to the bottom of the vessel
Cost effective
Sensor is quick and easy to install
User friendly
Visualised display of measurements

Process data

Measuring task:
Level measurement
Measuring point:
Tank
Measuring range up to:
1 m
Medium:
Liquids
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Changing media, short measuring range

Agitating tank

Level measurement and point level detection in an agitating tank

Application

In the pharmaceutical industry, numerous liquids with widely different properties are required. Liquid intermediate products must be made available and held ready for further processes. To ensure smooth, continuous production, reliable level measurement and point level detection are essential.

Your benefit

Reliable
Reliable measurement, unaffected by media properties
Cost effective
Long service life ensures uninterrupted operation for extended periods
User friendly
Non-contact measurement through glass

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
10 m
Medium:
Liquids with very different properties
Process temperature:
+20 … +35 °C
Process pressure:
0 … +35 bar
Special challenges:
Changing, aggressive and corrosive liquids

Flexible Intermediate Bulk Container (Bulk bag, BigBag)

Level measurement in a Flexible Intermediate Bulk Container (Bulk Bag)

Application

Granular raw materials are delivered and stored in Flexible Intermediate Bulk Containers (FIBC) also known as ‘Bulk Bags’ or ‘BigBags’. The raw materials are fed to the various process stages via conveyor belts or pneumatic lines. To ensure reliable supply to production, the levels in these FIBC’s need to be continuously monitored.

Your benefit

Reliable
High measurement certainty thanks to media-independent measurement
Cost effective
Reliable measurement ensures continuous production
User friendly
No dismounting of sensor necessary when changing the container, as measurement is possible right through the BigBag

Process data

Measuring task:
Level measurement
Measuring point:
Container
Measuring range up to:
4 m
Medium:
Granular raw materials
Process temperature:
-40 … +50 °C
Process pressure:
0 … 0 bar
Special challenges:
Measuring through the container

Drum coater storage tank

Level measurement and point level detection in the storage tank of a drum coater

Application

In the pharmaceutical industry, tablets are coated with colouring agents or active ingredients in a drum coater. This coating in the form of a liquid suspension, contains colouring or solids and is stored in a storage tank next to the drum. Itis sprayed into the drum via nozzles for even distribution on the surface of the tablets. Reliable level measurement in the storage tank is required to ensure that there is always enough of the liquid suspension for tablet coating. Overflow and dry run protection is provided by a reliable level switch.

Your benefit

Reliable
Approved materials acc. to FDA and EC 1935/2004
Cost effective
Continuous coating is ensured thanks to maintenance-free operation
User friendly
Simple mounting

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
2 m
Medium:
Colouring agent or solids-containing suspension
Process temperature:
+15 … +25 °C
Process pressure:
0 … +1 bar
Special challenges:
Low level, buildup

Capsule filling

Level and point level measurement during the capsule filling process

Application

The empty raw capsules and the active ingredient pellets are stored above the filling machine. Reliable level measurement is required here to ensure a continuous supply to the process. The capsules are only lightly stuck together and can be easily sucked apart by a vacuum, so that the upper part separates from the lower part. The pellets are then filled into the lower part of the capsule. After filling, the capsules are transported to the collecting vessels via a hose system. A level detection system serves as overfill protection in these containers.

Your benefit

Reliable
Certified materials according to FDA and EC 1935/2004 regulations
Cost effective
Uninterrupted filling of the capsules thanks to reliable measurement
User friendly
Automatic filling through continuous monitoring of the containers

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Vorratsbehälter
Measuring range up to:
1 m
Medium:
Active ingredient, raw capsules, filled capsules
Process temperature:
+20 … +25 °C
Process pressure:
0 … 0 bar
Special challenges:
Small fill levels, small fill level changes

Condenser (WFI)

Condenser pressure and point level measurement

Application

The so-called aqua purificata evaporated in the steam separator is condensed to high purity water (WFI) in the condenser. Inside the condenser there is a cooling system that cools the steam to make it condense. The feed of cooling liquid is monitored in the pipeline. Point level detection ensures that sufficient condensate is present to prevent steam from entering the WFI reservoir directly via the feed pipe.

Your benefit

Reliable
The materials used do not interact with the medium.
Cost effective
Maximum process efficiency is guaranteed through reliable measurement
User friendly
Standardized adapter system for all process fittings

Process data

Measuring task:
Pressure and point level measurement
Measuring point:
Tank and pipeline
Measuring range up to:
+3.5 bar
Medium:
Steam, WFI Water, Coolant
Process temperature:
+4 … +135 °C
Process pressure:
0 … +5 bar
Special challenges:
Influence from temperature, condensate formation

Steam separator (WFI)

Steam separator pressure measurement and point level detection

Application

In the production of ultrapure water (WFI), the process begins with aqua purificata being fed into the steam separator. The aqua purificata evaporates there and is fed into the condenser. Evaporation is effected by a heat exchanger supplied with saturated steam. To ensure that the heat exchanger is always covered with aqua purificata, reliable level detection is required. The pressure inside the steam separator must be kept constant in order to achieve maximum efficiency.

Your benefit

Reliable
The materials used do not interact with the medium
Cost effective
Maximum process efficiency is guaranteed through reliable measurement
User friendly
Standardized adapter system for all process fittings

Process data

Measuring task:
Pressure and point level measurement
Measuring point:
Tank and pipeline
Measuring range up to:
+3.5 bar
Medium:
Purified water, Sattdampf
Process temperature:
+50 … +135 °C
Process pressure:
0 … +5 bar
Special challenges:
Aseptic processes

Steam boiler

Level measurement and point level detection in process steam generation

Application

High process pressures and a highly compressed vapour phase are the normal operating conditions inside boilers. The size of the steam generator is what determines the quantity of saturated steam that can be fed into a heat exchanger. Reliable control of the water level and limitation of high and low water levels are therefore extremely important.

Your benefit

Reliable
High operational reliability under all process conditions
Cost effective
Simple to install, even in existing plants
User friendly
Maintenance-free operation

Process data

Measuring task:
Level measurement and point level detection
Measuring point:
Tank
Measuring range up to:
3 m
Medium:
Condensate
Process temperature:
+180 … +400 °C
Process pressure:
+6 … +160 bar
Special challenges:
High pressures and temperatures

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