Pharmaceutical Manufacturer Installs Nitrogen Generator

A site in the East Midlands, engaged in pharmaceutical product manufacturing, relied on high-pressure nitrogen gas cylinders to create a clean, dry, inert atmosphere for a spray dryer application. The cylinders had to be transported a considerable distance from the loading bay to the roof space plant room of a four-story building. This process posed several challenges, including manual handling, labour time, safe on-site transport, and storage of high-pressure gas. Additionally, the high cost of purchasing nitrogen gas in numerous single cylinders was a significant concern.

The site had stringent requirements for oxygen concentration, allowing for a percentage quality of nitrogen gas rather than parts per million (PPM). This provided an opportunity for cost reduction while maintaining a safety factor in the gas generator's purity. Any installation needed to occur within the same upper-floor plant room, which had the same access issues as moving high-pressure gas cylinders.

After conducting a detailed site survey, including air compressor data logging, Maziak proposed installing an Atlas Copco NGP35PCT Nitrogen Generator. This solution utilized the existing compressed air system and repurposed redundant dry air tanks for additional storage capacity. Key elements of the solution included:

• Specialised Transport and Installation: The new nitrogen generation equipment was offloaded and positioned by a specialist contractor using a bespoke transport frame. This ensured safe and precise placement in the required location.
• Efficient Piping and Power: The plant was connected using Mapress copper tubing and fittings, matching the existing piping infrastructure. A single-phase 5-amp power supply was provided locally by the site for Maziak engineers to connect to the nitrogen generator.
• Continuous Monitoring: An Analox gas analyser with an oxygen sensor was installed to continuously monitor the ambient environment for oxygen enrichment or depletion. In case of an out-of-specification reading, the sensor triggers an audible and visual alarm to warn workers of potential danger.

The implementation of the on-site nitrogen gas generation system resulted in the elimination of health and safety issues associated with using high-pressure gas cylinders, creating a safer working environment. It provided a reliable nitrogen gas supply that meets the purity and volume requirements for pharmaceutical production for years to come. The system enabled continuous real-time monitoring of nitrogen gas purity and volume, integrated with the site's Building Management System (BMS) for validation and traceability. Additionally, it delivered cost-effective, on-demand nitrogen gas production that automatically starts and stops with production use, offering a significant and provable return on investment (ROI).