Why Efficient HVAC Air Filtration is Vital for Pharmaceutical Manufacturing: The Key to Success in Oral Solid Dosage Manufacturing

Discover how to improve quality, safety and efficiency in pharma with advanced air filtration solutions.  

In the pharmaceutical industry, maintaining a controlled environment is essential for ensuring product quality and compliance with regulatory standards. One of the most critical components in manufacturing facilities is the HVAC system, particularly its air filtration capabilities. 

The need for stringent air filtration is heightened in oral solid dosage (OSD) production facilities where tablets and capsules are made because the process generates airborne particles. Efficient HVAC air filtration helps prevent contamination, controls particulate matter and ensures a sterile environment, protecting both the integrity of the pharmaceutical products and the safety of workers. 

Importance of Air Filtration in OSD Pharmaceutical Processing

Implementing robust HVAC air filtration systems is not just a regulatory necessity, but also a key factor in the overall success and safety of pharmaceutical manufacturing operations.

• Cross-Contamination

In OSD facilities, multiple products are often manufactured simultaneously, increasing the risk of cross-contamination. Airborne particulates from one production line can migrate to another, contaminating products and leading to batch rejections or costly recalls. Efficient air filtration systems capture and remove these particulates, minimizing the risk of contamination between products. High-efficiency particulate air (HEPA) filters, for instance, are capable of trapping particles as small as 0.3 microns, ensuring that cross-contamination is kept to a minimum.

• Maintaining Product Quality

Airborne particles can negatively affect the physical and chemical properties of OSD products. Dust, moisture and microbial contamination can compromise the stability, efficacy and safety of OSD tablets and capsules. Proper air filtration helps ensure a clean environment, preserving the integrity of active pharmaceutical ingredients (APIs) and excipients. 

• Quality Control and Regulatory Compliance

The pharmaceutical industry is subject to strict regulations from agencies such as the U.S. Food and Drug Administration (FDA) and the European Medicines Agency (EMA). These regulations include guidelines for air quality in manufacturing facilities, requiring specific air change rates, particulate counts and cleanliness levels. Efficient air filtration systems are essential for meeting these requirements and avoiding regulatory non-compliance, which can result in fines, production shutdowns or product recalls.

• Occupational Safety and Health Hazards

In addition to protecting the product, proper air filtration systems safeguard the health and safety of workers. OSD manufacturing can generate a significant amount of dust and particulate matter, which can pose respiratory hazards if inhaled. Exposure to these particles over time can lead to diseases such as asthma or chronic lung conditions. 

Challenges in Maintaining Air Quality in Pharmaceutical Processing Facilities

Maintaining optimal air quality in pharmaceutical processing facilities is a complex task, requiring careful attention to numerous factors that impact both the production environment and regulatory compliance. In OSD manufacturing, several key challenges need to be addressed to ensure a clean, controlled environment, from preventing particle contamination to maintaining energy efficiency and adhering to strict regulations like the FDA’s Current Good Manufacturing Practices (CGMP). Below are some of the most common challenges faced in providing clean air quality.

• Particle Contamination

Preventing airborne contaminants from infiltrating cleanrooms and processing areas requires highly efficient filtration systems. HEPA filters, which can capture a minimum of 99.97% of particles as small as 0.3 microns, are typically used to prevent contamination. However, even minor damage to these filters during installation or handling can render them ineffective. Camfil’s Megalam ES HEPA filters, made with strong ePTFE media, address this issue. The durable material is resistant to damage during shipping and installation, reducing the risk of compromised filters and avoiding costly downtime.

• Balancing Airflow and Energy Efficiency

Maintaining proper airflow is an absolute necessity  for pharmaceutical facilities, but it can be challenging to achieve without excessive energy cost.  HEPA filters, while critical for trapping contaminants,   increase resistance in HVAC systems, leading to higher energy consumption. To achieve the required airflow,  facilities must ensure that their HVAC systems, especially the fans,  are operating  at optimal capacity. Finding this balance is especially difficult in older facilities where HVAC systems and their fans struggle to deliver the proper airflow. 

In addition, as HEPA filters load with particles over time, resistance increases, further straining the system. To mitigate this issue, regular maintenance and filter replacements are necessary. However, newer filter designs, such as the Camfil Megalam ES, offer longer lifespans while maintaining airflow and efficiency. These filters are engineered to reduce pressure drop, which lowers energy consumption and enables facilities to maintain clean air without excessive operational costs.

• HEPA Filter Efficiency After Testing and Validation

Pharmaceutical facilities face another challenge in ensuring that HEPA filters maintain their efficiency after undergoing testing and validation. Oil aerosols, often used during OSD manufacturing processes, can degrade the performance of certain filter materials, reducing their ability to capture particles over time. This can result in a loss of filtration efficiency and necessitate premature replacement of the filters, which adds to operational expenses. However, Camfil’s Megalam ES has been designed to overcome this challenge as well. The filter’s ePTFE media is more resistant to oil aerosol exposure, ensuring that it maintains filtration efficiency throughout its lifecycle. This reliability helps facilities avoid the additional cost and disruption of replacing filters due to efficiency degradation following validation tests.

• Regulatory Compliance and CGMP Standards

To meet the FDA’s CGMP standards, facilities must conduct regular testing and validation of their HVAC systems, including air filtration performance. Any deviation from the required standards can lead to costly regulatory action. Therefore, investing in reliable, high-performance filters like Camfil’s Megalam ES can be a key factor in achieving consistent compliance because they offer durability, efficiency and resistance to common issues such as filter damage or aerosol contamination.

Key Areas in OSD Manufacturing that Require Efficient HVAC Air Filtration

OSD manufacturing encompasses a range of production processes, each of which requires tailored HVAC air filtration solutions to ensure optimal air quality. From the initial milling of raw materials to the final packaging of tablets and capsules, every step of the production process is vulnerable to contamination from airborne particulates. Ensuring that each of these areas is equipped with the appropriate level of filtration is essential for maintaining product quality, regulatory compliance and worker safety. 

Each of these key areas in OSD manufacturing presents unique air filtration challenges, and the appropriate filter rating depends on the specific needs of the environment. For general dust and particulate control, HVAC filters rated MERV 13/13A are effective at capturing an average of 85% of particles at 1 micron and larger in size, making them suitable for many areas within the facility. However, in more sensitive environments such as compression suites, coating areas and isolator areas, HEPA filters are essential. HEPA filters, which remove a minimum of  99.97% of particulates as small as 0.3 microns, provide the highest level of air filtration and contaminant capture.

Here are key areas within OSD facilities that demand efficient air filtration, highlighting the need for MERV 13/13A or higher and/or HEPA filters to capture harmful particulates.

• Milling, Grinding, and Blending Areas

Milling, grinding and blending processes are some of the most particle-intensive operations in OSD manufacturing. These activities generate significant amounts of dust and fine particulate matter, which can easily become airborne and contaminate other parts of the facility if not properly contained. In these areas, it is essential to use filters rated MERV 13/13A or higher to capture small particles that could compromise product quality or pose health risks to workers. In high-risk environments where ultrafine particles are a concern, higher efficiency filters such as HEPA or ULPA filters are required.

• Compression Suites

Compression suites, where powdered materials are compressed into tablets, are highly sensitive environments that require strict control over air quality. Particles generated during the compression process can be easily disturbed and become airborne, leading to cross-contamination if not properly managed. The use of high-efficiency filtration systems, such as HEPA filters, helps maintain a clean environment by removing fine dust particles generated during tablet formation. By controlling particulate levels, these filters also help ensure the stability and uniformity of the finished dosage forms.

• Coating Areas

Coating areas, where tablets are coated with polymers or other substances, require an even greater level of air quality control. The coating process often involves the use of organic solvents or aqueous solutions, which can create particulate aerosols. Ensuring the cleanliness of the air in these areas is critical to avoid contamination that could affect the appearance, stability, or efficacy of the coated tablets. HEPA filters are typically used in coating areas to ensure the highest level of particulate removal and to maintain the required environmental conditions for proper tablet coating.

• Conveying and Loading Areas

Conveying and loading areas, where materials are transported and loaded into machines or packaging systems, can be sources of particulate contamination if air filtration is inadequate. Dust and particulates can be generated during material transfer, potentially contaminating the final product. In these areas, MERV 13/13A filters and higher are typically sufficient to capture the dust and particulate matter generated during material handling. For facilities dealing with high-value or sensitive materials, higher-rated filters like HEPA filters may be necessary to ensure particulate-free environments.

• Isolator Areas

Isolator areas, where hazardous or sensitive materials are handled, require particularly stringent air filtration to protect both the product and the personnel. These areas often operate under negative pressure to prevent contamination from spreading to other parts of the facility. The use of HEPA filters is crucial in isolator areas to ensure that even the smallest particles are captured and removed from the air. In these controlled environments, any breach in air quality could lead to product contamination or expose workers to hazardous substances, making efficient filtration systems non-negotiable.

• Downflow Booths

Downflow booths are designed to provide a clean, controlled environment for operators working with powders or other potentially hazardous materials. These booths rely on a constant flow of filtered air to push airborne particles away from the operator and into the filtration system. In downflow booths, HEPA filters are often used to capture fine particulates and prevent them from circulating back into the workspace. The controlled airflow combined with high-efficiency filtration ensures that the work environment remains free from contaminants, safeguarding both the product and the operator.

Impact of Air Filtration on Occupational Health and Safety

In pharmaceutical manufacturing, maintaining a clean and controlled environment is not only critical for product quality but also essential for protecting the health and safety of employees. Airborne contaminants, including dust, chemical fumes and microbial particles, can pose serious health risks to workers if not effectively managed. Efficient HVAC systems, equipped with high-performance air filters, play a crucial role in mitigating these risks by improving indoor air quality (IAQ) and ensuring a safe working environment.

• Protecting Employees from Airborne Contaminants

OSD manufacturing processes like milling, blending, compression and coating can generate significant amounts of airborne particulates. These contaminants can include pharmaceutical dust, active ingredients and excipients, some of which may be hazardous if inhaled over prolonged periods. Exposure to these particles can lead to respiratory issues, allergic reactions, and other occupational health hazards. Furthermore, the inhalation of fine particulates or chemical fumes can result in long-term health conditions, such as asthma or chronic obstructive pulmonary disease (COPD). In areas where highly potent APIs are handled, the need for effective filtration becomes even more critical to prevent health risks from inhalation or skin contact.

• Maintaining a Safe Working Environment

A well-designed HVAC system with efficient air filtration not only protects workers from particulate exposure but also helps maintain overall environmental safety. Controlling airborne contaminants reduces the risk of combustible dust explosions, which can occur when fine powders accumulate in the air. When working simultaneously with industrial dust collection systems, proper HVAC air filtration and ventilation contributes to providing an added layer of protection for employees.

Moreover, maintaining a safe and healthy working environment contributes to overall employee well-being and productivity. Workers are less likely to experience respiratory problems, fatigue or irritation when the air they breathe is clean and free of contaminants. This can lead to lower absenteeism rates, fewer work-related illnesses and improved job satisfaction.

• The Role of MERV 13/13A or Higher Filters in Improving IAQ

One of the most effective ways to improve IAQ in pharmaceutical manufacturing facilities is through the use of air filters rated MERV 13/13A or higher. MERV 13A filters are designed to capture an average of 85% of particles, including dust, mold spores and bacteria, at 1 micron in size and larger. These filters are particularly effective at removing the particulates generated during OSD processes, thereby reducing the concentration of airborne contaminants in the work environment.

Energy Efficiency in HVAC Air Filtration

HVAC air filtration systems account for a significant portion of a facility’s energy consumption, especially when lower quality high-efficiency filters are in use. These types of filters, while technically labeled MERV 13 or higher, may not maintain that effectiveness.  They often create high resistance to airflow, forcing HVAC systems to work harder and consume more energy to maintain the required air changes and ventilation rates. This increased energy demand not only drives up operational costs but can also lead to greater wear and tear on HVAC equipment.

Innovative air filters like Camfil’s 30/30 Dual 9, Durafil ES3 and Absolute VG are designed to minimize this resistance without sacrificing filtration efficiency. These filters are engineered to reduce pressure drop, which is the amount of resistance air encounters as it passes through the filter. Lower pressure drop means that HVAC systems require less energy to maintain airflow, resulting in significant energy savings over time. For facilities that run HVAC systems continuously to meet regulatory requirements for air quality, these savings can be substantial.

• Camfil’s 30/30 Dual 9:  High Efficiency with Low Resistance

The Camfil 30/30 Dual 9 air filter is an excellent example of how modern filtration technology can reduce energy consumption while maintaining high levels of efficiency. This pleated panel filter features a dual-layer design that maximizes dust-holding capacity, allowing it to capture more particles over a longer period without clogging. Despite its high efficiency, the 30/30 Dual 9 is designed to have a low initial resistance, meaning that HVAC systems do not need to work as hard to pull air through the filter. By reducing the strain on the HVAC system, the 30/30 Dual 9 helps lower energy costs while maintaining clean air standards. Its long service life, guaranteed for 9 to 12 months, further enhances energy efficiency by reducing the frequency of filter changes, which not only minimizes labor costs but also reduces waste and environmental impact.

• Durafil ES3:  Long Service Life and Energy Savings

Camfil’s Durafil ES3  is a high-efficiency air filter designed for extended service life, offering both energy savings and superior filtration performance. The filter’s unique design includes a large filter surface area, which increases its dust-holding capacity and allows for longer intervals between filter changes. This results in less frequent maintenance, reducing operational disruptions and the associated labor costs.

Additionally, the Durafil ES3’s low-pressure drop characteristics make it a highly energy-efficient choice for facilities that require continuous HVAC operation. By maintaining consistent airflow with minimal energy expenditure, this filter is guaranteed to reduce the overall energy footprint of pharmaceutical facilities without compromising air quality standards.

• Absolute VG:  Energy-Efficient HEPA Filters

For areas within pharmaceutical facilities that require HEPA-level air filtration, such as isolator areas or cleanrooms, Camfil’s Absolute VG HEPA filters offer an energy-efficient solution. The Absolute VG air filter is designed with advanced media that delivers high-efficiency particulate capture while minimizing resistance to airflow. This reduces the load on HVAC systems, helping facilities maintain the high levels of air quality required for regulatory compliance while keeping energy costs in check.

The Absolute VG air filter’s long service life further contributes to its energy efficiency. By reducing the frequency of filter replacements, this filter lowers operational costs and minimizes disruptions to the production process. Its ability to maintain high filtration standards over an extended period makes it an ideal solution for pharmaceutical environments where HEPA filtration is critical.

Camfil’s Air Filtration Solutions for Pharma

To meet the unique challenges faced in OSD production, Camfil offers a range of products specifically designed to address the critical air quality demands of pharmaceutical environments. Key Camfil products—Durafil V-Style Filters, Absolute VG HEPA Filters, Megalam® ES, and the CamCleaner CC500—provide tailored solutions to meet these challenges.

• Durafil V-Style Filters:  High Efficiency with Long Service Life

Durafil V-Style Filters are engineered for environments that require high-efficiency particulate removal and long filter life, making them ideal for pharmaceutical manufacturing facilities. The V-shaped design allows for a larger surface area, which increases dust-holding capacity and extends the filter’s lifespan. This means fewer filter changes, reduced maintenance costs, and less downtime—key benefits in facilities that need continuous air filtration.

Durafil filters also boast a low-pressure drop, which translates to significant energy savings. By minimizing resistance to airflow, these filters help HVAC systems operate more efficiently, reducing overall energy consumption. For pharmaceutical manufacturers looking to maintain a high level of air quality while optimizing operational costs, Durafil V-Style Filters provide a robust and energy-efficient solution.

• Absolute VG HEPA Filters:  Superior Particle Removal for Sensitive Areas

The Absolute VG HEPA air filter is a high-efficiency filter designed to meet the strictest air quality standards in pharmaceutical environments. Capable of capturing 99.99% of airborne particles as small as 0.3 microns, this filter is ideal for use in cleanrooms, isolators and other areas where HEPA-level filtration is required. Its advanced filter media minimizes pressure drop, reducing the strain on HVAC systems and ensuring long-term energy savings. 

• Megalam® ES: Durable and Reliable HEPA Filtration

Megalam® ES is another high-performance HEPA filter from Camfil, designed specifically to withstand the challenges of pharmaceutical manufacturing environments. Made with ePTFE media, the Megalam ES is resistant to damage during shipping, handling and installation, making it a reliable choice for facilities that need durable filtration solutions. Its robust construction reduces the risk of filter damage, minimizing unplanned downtime and the costs associated with frequent filter replacements.

The Megalam ES also maintains its 99.995% efficiency throughout its lifecycle, even after exposure to oil aerosols used during testing and validation. This ensures that the filter continues to perform at peak levels, capturing fine particulates and maintaining clean air in critical areas like compression suites and coating rooms. Its long service life and consistent performance make the Megalam ES a cost-effective solution for facilities that require reliable HEPA filtration without sacrificing durability or efficiency.

• CamCleaner CC500:  Portable Air Filtration for Flexible Use

The CamCleaner CC500 portable air filtration unit is designed for flexibility in pharmaceutical facilities. It is particularly useful for supplemental air filtration in areas where additional filtration is needed temporarily, or where permanent installations are not feasible. Equipped with a MERV 9/9A pre-filter followed by a 99.99% efficient HEPA filter, the CC500 effectively captures dust, fumes and other airborne contaminants, providing clean air for employees and maintaining product safety.

One of the key advantages of the CamCleaner CC500 is its portability, allowing it to be moved to different areas of a facility as needed. This makes it an ideal solution for pharmaceutical manufacturers that need adaptable air filtration to respond to changing conditions or localized air quality issues. The unit is also energy efficient, designed to operate quietly while providing powerful air cleaning performance.

HVAC Filtration for Cleanrooms and Critical Areas

Cleanrooms and other critical areas in pharmaceutical manufacturing require the most stringent air quality controls to prevent contamination and ensure product integrity. These environments are subject to strict regulations, and even the smallest airborne particles can compromise the production process. To meet the rigorous standards set by the pharmaceutical industry, including those mandated by organizations like the FDA and ISO, HVAC systems in cleanrooms must be equipped with ultra-efficient filtration technologies such as HEPA and ULPA (Ultra-Low Penetration Air) filters. These filters prevent particulate contamination, ensuring that the cleanroom remains compliant with strict air quality classifications such as ISO 14644-1, which governs cleanroom standards. 

HEPA filters, capable of capturing a minimum 99.97% of particles as small as 0.3 microns, are often used in cleanrooms and other sensitive environments. However, certain pharmaceutical processes demand an even higher level of filtration, particularly when dealing with ultra-sensitive or high-potency products. In these cases, ULPA filters are required. ULPA filters remove a minimum of 99.999% of particles down to 0.12 microns, offering an additional layer of protection for the most critical environments.

Camfil’s ULPA filtration solutions are specifically designed to meet the highest air quality demands of pharmaceutical cleanrooms. Camfil’s ULPA filters provide exceptional particle capture efficiency, ensuring that even the most challenging cleanroom environments can maintain ultra-low particle counts. 

Camfil’s Megalam® filters, particularly the Megalam ES series, provide an additional layer of protection in cleanrooms and critical areas. Designed with durable ePTFE media, Megalam filters are resistant to damage, ensuring that their performance is uncompromised when they are installed. These filters are commonly used in cleanroom ceiling grids, fan filter units, and other critical air handling systems where air quality must remain consistently high. 

Pre-Filtration Solutions to Extend HVAC System Life

Pharmaceutical facilities often employ multi-stage HVAC systems to maintain demanding air quality standards, especially in cleanrooms and other critical areas. These systems use different levels of filtration, with pre-filters serving as the first line of defense. Pre-filters are tasked with capturing larger particulates—such as dust, pollen and other airborne debris—before the air moves to the more efficient secondary and final filters like HEPA and ULPA filters.

By removing large contaminants early in the filtration process, pre-filters reduce the load on downstream filters. This is crucial because high-efficiency filters, while capable of capturing ultra-fine particles, can quickly become clogged or damaged if exposed to excessive amounts of larger particulates. When these filters become overloaded, they not only lose their efficiency but also require more frequent replacements, increasing operational costs and downtime.

Pre-filtration, therefore, plays a critical role in extending the lifespan of more expensive filters, lowering maintenance costs, and keeping HVAC systems running smoothly. Additionally, by protecting downstream filters, pre-filters help optimize the overall performance of the HVAC system, ensuring that airflow remains consistent, and energy consumption is minimized.

• Camfil’s 30/30 Dual 9 Pre-filtration Solution

One of the most effective pre-filtration solutions on the market is Camfil’s 30/30 Dual 9 air filter. Designed for durability and efficiency, the 30/30 Dual 9 is a pleated panel filter that offers superior dust-holding capacity and low initial resistance to airflow, making it ideal for use in multi-stage HVAC systems.

The dual-layer media of the 30/30 Dual 9 filter maximizes its ability to capture and retain large particulates. The outer layer traps larger particles, while the inner layer captures smaller debris, ensuring that downstream filters are protected from a wide range of contaminants. This dual-stage filtration extends the service life of the filter and reduces the need for frequent replacements.

Moreover, the low-pressure drop of the 30/30 Dual 9 means that HVAC systems do not need to work as hard to maintain airflow. This not only reduces energy consumption but also prolongs the operational life of the entire HVAC system. 

• Reducing Total Cost of Ownership

The total cost of ownership (TCO) for HVAC systems in pharmaceutical manufacturing is impacted by a variety of factors, including filter replacement costs, energy usage, and system downtime. Pre-filtration solutions like the 30/30 Dual 9 help reduce TCO by extending the life of downstream filters and minimizing energy consumption. By trapping larger particles before they reach high-efficiency filters, the 30/30 Dual 9 helps reduce the frequency of HEPA and ULPA filter replacements, which are more costly than pre-filters.

In addition to lowering filter replacement costs, pre-filters help prevent system failures or unplanned downtime caused by clogged or damaged filters. By keeping the HVAC system running efficiently and maintaining optimal airflow, pre-filters contribute to the longevity and reliability of the entire air filtration system.

Compliance with CGMP Regulations and Industry Standards

In pharmaceutical manufacturing, ensuring product safety, quality and consistency is paramount. For OSD manufacturing facilities, adherence to CGMP regulations, as mandated by the U.S. FDA, is critical. CGMP regulations establish strict guidelines for maintaining contamination-free environments, ensuring that air quality within production areas meets stringent standards. Efficient HVAC air filtration systems play a vital role in achieving and maintaining compliance, ensuring that facilities can consistently produce high-quality pharmaceutical products.

• Key requirements under CGMP include:
• Contamination Control:  Facilities must implement measures to prevent contamination from particulates, microorganisms and cross-contamination between different products.
• Environmental Monitoring:  Manufacturing areas, particularly cleanrooms and critical zones must undergo regular environmental monitoring to ensure compliance with air cleanliness standards.
• Air Filtration:  HVAC systems must be equipped with appropriate air filters in critical areas to maintain a clean, contaminant-free environment. Filtration systems must be validated and regularly maintained to ensure optimal performance.
• Cleanroom Standards:  Areas where oral solid dosages are handled, processed or packaged must meet specific air cleanliness levels, such as those outlined in ISO 14644-1, which governs particle count classifications for cleanrooms.
• Documented Procedures:  All processes related to HVAC system maintenance, air filtration, and environmental control must be fully documented to comply with regulatory audits and inspections.

Failure to meet CGMP regulations can result in product recalls, regulatory warnings, or facility shutdowns, underscoring the importance of compliant air filtration solutions in OSD manufacturing.

•  How HVAC Air Filtration Supports CGMP Compliance

An efficient HVAC air filtration system is essential for maintaining a controlled environment that is free of contaminants, which directly impacts CGMP compliance. Proper filtration prevents airborne contaminants, including dust, bacteria, and cross-product particulates, from entering sensitive production areas. This is especially critical in OSD manufacturing, where even minor contamination can compromise product quality, safety, and efficacy.

Key benefits of HVAC air filtration in supporting CGMP compliance include:

• Particle Removal:  High-efficiency filters, such as MERV 13/13A or higher and HEPA filters, are required to capture airborne particles and microorganisms that could compromise product safety. These filters ensure that air within production areas meets the cleanliness standards mandated by CGMP and ISO classifications.
• Contamination Control:  By preventing the introduction of contaminants into the production environment, HVAC air filtration systems support cross-contamination prevention—one of the core principles of CGMP.
• Environmental Monitoring and Validation:  Efficient air filtration enables facilities to meet environmental monitoring requirements of CGMP by maintaining stable air quality and consistent airflow. Air filtration systems must undergo regular validation and testing to demonstrate compliance, ensuring that the HVAC system is functioning as required.

How to Implement an Effective Air Filtration Strategy in Pharma Facilities

Facility managers must take a systematic approach to design, procure, install, and maintain air filtration systems that meet the unique needs of their operations. Below are practical steps to create a robust air filtration strategy.

Assess Facility Requirements

Before designing an air filtration system, conduct a comprehensive assessment of the facility’s air quality needs. This includes:

• Identifying Critical Areas:  Determine which areas require higher levels of filtration (for example cleanrooms, production suites and packaging areas). Each area may have specific air cleanliness requirements based on regulatory standards.
• Understanding Environmental Conditions:  Evaluate existing conditions such as airflow patterns, temperature, humidity and the types of particulates typically present in the environment.
• Regulatory Compliance:  Review CGMP regulations and relevant industry standards, such as ISO classifications, to understand the specific filtration requirements for your operations.

Choose Appropriate Filtration Solutions

Select filtration solutions that align with the facility’s needs and regulatory requirements. Key considerations include:

• Filter Styles:  Use a combination of pre-filters and high-efficiency filters (HEPA or ULPA) to capture both large and small particles effectively. Pre-filters help extend the life of high-efficiency filters by capturing larger particulates.
• Filter Ratings:  Only choose filters with a MERV A value, and rated  13A or higher for critical areas, ensuring compliance with air quality standards.
• Material Selection:  Select filters made from durable materials, such as Camfil’s Megalam® ES filters, which are resistant to damage during handling and offer consistent performance throughout their service life.

Develop a Procurement Strategy

Implement a strategic procurement process to ensure the timely acquisition of high-quality air filtration products:

• Vendor Selection:  Research and select reputable vendors that specialize in air filtration solutions for the pharmaceutical industry. Consider factors such as experience, active in technical organizations such as ASHRAE, product quality, customer service and delivery timelines.
• Bulk Purchasing:  If applicable, consider bulk purchasing agreements to reduce costs and ensure consistent supply, especially for critical filters.
• Inventory Management:  Establish a system for monitoring filter inventory levels to avoid stockouts and ensure timely replacements.

Plan for Installation

Effective installation is critical for the performance of air filtration systems. Consider the following steps:

• Professional Installation:  Hire experienced professionals for the installation of filtration systems, especially for HEPA and ULPA filters. Proper sealing and mounting are essential to prevent leaks caused by poor handling that are only detected during startup that create unnecessary downtime.
• System Testing:  After installation, conduct thorough testing, such as airflow and particle count assessment, to ensure the system meets specified performance criteria.
• Documentation:  Maintain detailed records of the installation process, including filter specifications, installation dates and test results for future reference and regulatory compliance. Every HEPA or ULPA filter should have an individual factory test result available upon request.  

Implement a Maintenance Program

Regular maintenance is essential to ensure the longevity and effectiveness of air filtration systems. Establish a comprehensive maintenance program that includes the following.

• Routine Inspections:  Schedule regular inspections of air filters and HVAC systems to assess performance and identify any issues early.
• Filter Replacement Schedule:  Develop a filter replacement schedule based on manufacturer recommendations, usage patterns, and environmental monitoring data. Ensure that high-efficiency filters are replaced as needed to maintain compliance.
• Cleaning Protocols:  Implement cleaning protocols for the HVAC system to prevent dust accumulation and maintain optimal airflow. This includes cleaning ductwork, fan units and other components of the air handling system.
• Performance Monitoring: Continuously monitor air quality parameters, such as particle counts and airflow rates, to ensure the filtration system is performing as expected. Utilize real-time monitoring systems for proactive management.

Train Staff and Raise Awareness

Educating staff on the importance of air filtration and best practices is key to maintaining compliance and air quality:

• Training Programs:  Develop training programs for facility personnel focused on the significance of air filtration in maintaining product quality and compliance.
• Awareness Campaigns:  Foster a culture of awareness about the impact of air quality on health and safety in the workplace. Encourage staff to report any issues or concerns related to air filtration systems.

FAQs on Efficient HVAC Air Filtration in Oral Solid Dose Pharmaceutical Processing

As the pharmaceutical industry prioritizes product quality and regulatory compliance, many facility managers have questions regarding efficient HVAC air filtration systems for OSD manufacturing. Below are some common questions and answers to help clarify the importance and implementation of effective air filtration strategies.

• What is CGMP and how does it relate to HVAC filtration in pharma?

CGMP, or Current Good Manufacturing Practices, are FDA regulations designed to ensure that pharmaceutical products are consistently produced and controlled according to quality standards. In OSD pharmaceutical processing, CGMP mandates that HVAC systems, including air filtration, maintain cleanroom environments by controlling airborne contaminants. Proper filtration helps meet CGMP requirements by ensuring the air quality that is necessary to prevent contamination during drug manufacturing

• What is the best HVAC filter for oral solid dosage manufacturing?

For OSD manufacturing, high-efficiency particulate air (HEPA) filters are the gold standard. These filters can trap a minimum of  99.97% of particles as small as 0.3 microns, making them ideal for maintaining clean air in pharmaceutical facilities. A multi-stage filtration system that includes Minimum Efficiency Reporting Value with Appendix J (MERV A) 13A filters and HEPA filters is often recommended to ensure a high level of contamination control.

• How does HVAC air filtration prevent cross-contamination?

HVAC filtration prevents cross-contamination by trapping airborne particles such as dust, microbes, and chemicals that could transfer from one area to another within the facility. Advanced filtration systems, including HEPA filters, create controlled airflow patterns that maintain room pressure differentials, further reducing the risk of cross-contamination between production areas and storage zones.

• What are MERV 13 filters, and why are they important?

MERV 13 filters are a type of air filter that captures particles as small as 0.3 microns, including bacteria, dust, mold spores and other airborne contaminants. These filters are crucial in pharmaceutical environments as they provide an additional layer of protection before air reaches the HEPA filters, helping to extend the HEPA filters’ lifespan and improve overall air quality in the facility.

• Why are MERV A-rated filters preferred?

Some air filters are manufactured with synthetic coarse fibers that rely on a temporary electrostatic change to achieve higher MERV ratings. This charge can fade over time which lessens the filter’s efficiency at capturing particles. The MERV A rating indicates the filter’s minimum efficiency over its entire service life.

• How often should HEPA filters be replaced in pharma facilities?

The changeout schedule for HEPA filters in pharmaceutical facilities is dependent on the facility’s operational conditions, air quality, and quality of the HEPA filter.  Regular testing and validation are required to ensure that the filters are functioning at optimal efficiency. Preventive maintenance schedules should be based on the filter manufacturer’s recommendations and the facility’s air quality monitoring results.

• What is the energy cost impact of advanced air filtration?

Advanced HVAC  systems that include HEPA filters and multiple stages of filters, can increase energy costs due to higher air resistance that requires more energy to push air through the filters. However, filters with a low average resistance to airflow over their service life installed in modern energy-efficient HVAC systems with variable-speed drives,can help offset these costs. While there may be a higher upfront cost in the system, the benefits of maintaining cleanroom standards and preventing contamination outweigh these expenses in critical pharmaceutical environments. Regular filter maintenance also helps optimize system performance and reduce unnecessary energy consumption.

Conclusion – The Critical Need for Advanced Air Filtration in Pharma Manufacturing

In the highly regulated and quality-driven world of pharmaceutical manufacturing, particularly in OSD processing, efficient HVAC air filtration is not just a requirement, it is a cornerstone of product safety and integrity. As the industry faces increasing demands for compliance with stringent CGMP regulations and the need for consistent product quality, the role of advanced air filtration systems becomes ever more critical.

Effective air filtration helps mitigate risks associated with airborne contaminants, cross-contamination, and compromised product quality, ultimately protecting both the end user and the facility’s reputation. By utilizing high-efficiency filters, such as HEPA and ULPA filters, pharmaceutical manufacturers can maintain cleanroom standards and provide a safe working environment for employees, thus ensuring operational excellence.

Camfil’s comprehensive range of air filtration solutions is designed specifically to address the unique challenges faced by pharmaceutical manufacturers. From pre-filtration systems that protect downstream filters to high-efficiency HEPA filters that ensure optimal air quality in critical areas, Camfil provides the technology and expertise needed to create a reliable and effective air filtration strategy. By investing in Camfil’s advanced filtration solutions, pharmaceutical facilities can achieve regulatory compliance, enhance product quality and safeguard the health and safety of their workforce.

For more information about Camfil’s air filtration solutions for OSD pharmaceutical manufacturing, visit https://www.camfil.com/en-us/industries/life-sciences/pharmaceutical-osd-manufacturing. 

The post Why Efficient HVAC Air Filtration is Vital for Pharmaceutical Manufacturing: The Key to Success in Oral Solid Dosage Manufacturing appeared first on Air Filters for Clean Air.

from Air Filters for Clean Air