Camfil Molecular Filtration: Optimizing Sterilant Control: Advanced Air Filtration Solutions for Critical Industries

Maintaining a sterile environment in industries like food and beverage, healthcare, pharmaceutical, and industrial manufacturing is a critical task that requires stringent measures. Among these procedures, controlling sterilants plays a pivotal role. Sterilants, such as hydrogen peroxide vapor, peracetic acid, and ethylene oxide, are essential for disinfection but present unique challenges that demand advanced solutions. In this article, we’ll examine how molecular air filtration technology can optimize sterilant control and enhance air quality in critical environments.

Understanding the Challenges of Sterilant Control

Sterilants are indispensable for achieving sterilization in various industries, but their use comes with significant challenges. Understanding these challenges is the first step toward developing effective solutions.

Health Risks to Workers

Exposure to sterilants can pose health risks such as respiratory issues, skin irritation, and long-term health complications. For example, hydrogen peroxide vapor (HPV) causes respiratory discomfort and eye irritation. Ethylene oxide (EtO) is known for its carcinogenic properties with potential long-term effects.

Product Contamination

Sterilants, when not effectively controlled, can compromise product integrity when residual sterilants react with product components. In addition, they can contaminate food, pharmaceuticals, or medical devices during production.

Equipment Corrosion 

Sterilants can corrode sensitive equipment and surfaces, leading to increased maintenance costs, reduced equipment lifespan, and compromised operational efficiency.

Interference with Sensitive Processes

Certain sterilants may interfere with precision processes or equipment calibration, causing production delays or failures.

Molecular Air Filtration:  An Advanced Solution

Molecular air filtration is a transformative technology that targets gaseous contaminants at the molecular level. Unlike traditional air filtration systems, molecular air filters offer specialized solutions to sterilant control challenges.

What Is Molecular Air Filtration?

Molecular air filtration employs advanced adsorbent materials, such as activated carbon,  configured in an air filter such as a V-bank, bag, pleated panel filter, or in bulk form such as in cylinders, and V-cell panel filters,  to capture and neutralize harmful gases and vapors.

Key Benefits of Molecular Air Filtration

• Targeted Removal:  Filters can be customized to target specific sterilants.
• High Efficiency:  Achieves removal rates up to 99.9% for sterilants like hydrogen peroxide vapor.
• Extended Lifespan:  Filters last longer with minimal performance degradation.
• Enhanced Air Quality:  Reduces harmful gases, improving worker safety and compliance with air quality standards.

Camfil’s Molecular Air Filtration Solutions

Camfil is a global leader in air filtration technology, offering cutting-edge solutions tailored to sterilant control needs. Below are some of their most effective products.

CamCarb VG Molecular FIlters

• Purpose:  Removes a wide range of molecular contaminants.
• Features: High-capacity adsorption for varied sterilants, including hydrogen peroxide and peracetic acid.
• Applications:  Suitable for healthcare, pharmaceutical, and industrial facilities.

 CityCarb Filters

• Purpose: Dual-functionality for particulate and molecular contaminant removal.
• Features: High-efficiency MERV 15 particulate filter with high adsorption capacity.
• Applications: Multifunctional solution for facilities requiring particulate and sterilant control.

CamPure Filter Media

• Purpose:  Ensures ultra-high purity air for critical environments.
• Features:  Designed for environments requiring stringent disinfection and sterilization.
• Applications:  Ideal for clean rooms and pharmaceutical labs.

Real-World Success:  A Pharmaceutical Case Study

One of the world’s largest pharmaceutical companies, headquartered in the northeastern United States turned to Camfil to help it address unpleasant ethanol-based odors in the pharmaceutical manufacturer’s lab and cold storage area where starting fermentation samples were stored. 

The company implemented Camfil’s freestanding CamCleaner Vertical mobile air cleaner configured with 20 CamCarb cylindrical air filters to provide optimum removal of molecular gaseous contaminants. 

Air quality concerns and odor issues were immediately eliminated. Employees in the lab, storage area and nearby workspaces now report zero odor presence, with no buildup or sudden bursts of unpleasant air. Camfil’s industrial vertical air cleaning unit has a long life expectancy in the application with a carbon filter life cycle of 18 months for long-term air quality control.

Real-World Success:  Desulfurization of Biogas Case Study

The case study highlights the effectiveness of Camfil’s CamPure 32 molecular filtration media in desulfurizing biogas by removing hydrogen sulfide (H2S) during anaerobic digestion. A French farm cooperative, GAEC de la Pépinière, which operates a biogas production unit, faced challenges with high H2S concentrations that could corrode equipment and hinder energy production.

By implementing CamPure 32, the farm achieved complete removal of H2S, ensuring cleaner biogas production. The air filtration media lasted for eight months, capturing 228 kg of H2S before breakthrough, reducing operational costs. The lower corrosion risks helped to maintain operational efficiency and reduce maintenance downtime. The success of this implementation demonstrates the utility of advanced molecular air filtration in optimizing biogas production while addressing environmental and operational challenges​.

Best Practices for Implementing Molecular Air Filtration

To ensure the successful adoption of molecular air filtration, follow these best practices:

Conduct a Comprehensive Assessment

• Analyze the specific sterilants used in your facility.
• Identify areas of high exposure and potential risk.

Select the Right Air Filter Media

• Collaborate with experts to match air filter materials with targeted contaminants.
• Consider sterilant-specific requirements for optimal air filtration.

Monitor Air Quality

• Conduct periodic air quality tests to evaluate system performance.
• Use real-time monitoring tools for continuous oversight.

Maintain and Replace

• Follow the manufacturer’s guidelines for air filter replacement schedules.
• Clean and maintain air filters regularly to ensure consistent performance.

Train Staff

• Educate staff about the importance of air filtration systems.
• Train teams on system operation, monitoring, and maintenance procedures.

The Strategic Advantage of  High-Efficiency Air Filtration

Interest in advanced molecular air filtration is not just about meeting regulatory compliance; it’s a strategic move toward operational excellence. The benefits of enhanced safety protect workers from harmful sterilant exposure and minimize workplace accidents and health-related costs. Advanced air filtration also improves product quality by eliminating risks of contamination during production and ensuring consistent product safety and reliability.

Cost savings of implementing molecular air filtration include cost savings through lower maintenance and repair costs by reducing equipment corrosion and extending lifespan of HVAC systems and air filtration units. It also helps you to meet stringent industry standards for air quality and safety and avoid fines and penalties associated with non-compliance.

All of these benefits add up to giving you a competitive edge by positioning your facility as a leader in sustainability and worker safety, which will attract partners and clients who value high standards in operations.

FAQs About Sterilant Control and Molecular Air Filtration

1. What are sterilants, and why are they used?

Sterilants are chemical agents like hydrogen peroxide, peracetic acid, and ethylene oxide used to disinfect environments and ensure sterility in industries such as healthcare and pharmaceuticals.

2. How does molecular filtration improve sterilant control?

Molecular air filtration targets and removes gaseous sterilants at the molecular level, reducing exposure risks, improving air quality, and protecting equipment from corrosion.

3. Can molecular filters be integrated into existing HVAC systems?

Yes, molecular air filters like Camfil’s solutions are designed for seamless integration with existing HVAC systems, making upgrades cost-effective and efficient.

4. What are the maintenance requirements for molecular filters?

Molecular air filters require regular inspection, cleaning, and timely replacement based on manufacturer guidelines to maintain optimal performance.

5. Are there specific molecular air filters for different sterilants?

Yes, molecular air filters can be customized to target specific sterilants and contaminants, ensuring maximum efficiency.

6. How can industries benefit from investing in advanced air filtration systems?

Industries benefit through improved safety, reduced maintenance costs, enhanced product quality, and compliance with regulatory standards.

Conclusion

Managing sterilants effectively is crucial for ensuring safety, maintaining product quality, and achieving compliance in critical industries. Camfil’s molecular air filtration solutions provide a powerful means to address the unique challenges posed by sterilants. By implementing these advanced systems and adhering to best practices, facilities can enjoy improved air quality, cost savings, and a strategic advantage in their operations.

To discover more ways air filtration solutions from Camfil USA can help you protect people, processes and the environment, visit us at www.camfil.us/. 

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Enhancing Indoor Air Quality and Corrosion Monitoring with Camfil’s Advanced Solutions

Indoor Air Quality (IAQ) significantly influences health and productivity in industrial and manufacturing facilities. Poor air quality can lead to respiratory issues, allergies and decreased cognitive function. Prolonged exposure to airborne pollutants such as fine particulate matter (PM2.5), volatile organic compounds (VOCs) and chemical fumes can exacerbate chronic conditions like asthma and cardiovascular diseases. Moreover, inadequate IAQ can increase employee absenteeism and reduce workplace efficiency.

In addition to creating a healthier work environment, implementing effective IAQ strategies is essential for protecting valuable assets. Prioritizing IAQ as part of a corrosion management strategy can significantly prolong the lifespan of infrastructure and equipment and lower maintenance costs. Investing in IAQ management is a proactive approach that enhances the well-being of personnel, protects valuable equipment, and maximizes operational efficiency. 

Understanding IAQ Monitoring

IAQ quality monitoring involves assessing the levels of pollutants in the air to ensure they remain within safe limits and comply with environmental regulations. Common contaminants monitored include particulate matter, VOCs and other harmful gases.

Particulate matter (PM) refers to a mixture of tiny solid particles and liquid droplets suspended in the air. The classification of particulate matter is based on the diameter of these particles, which significantly impacts their behavior in the atmosphere and their effects on health and the environment.

PM1 refers to particles with a diameter of 1 micrometer (µm) or smaller. Sources of PM1 include combustion particles (e.g., from engines and industrial processes), secondary particles formed from chemical reactions (e.g., sulfates and nitrates) and some ultrafine particles. PM1 can penetrate deeply into the lungs and may even enter the bloodstream, posing risks such as cardiovascular and respiratory issues.

PM2.5 refers to particles with a diameter of 2.5 micrometers or smaller. PM2.5 can be generated by combustion (e.g., vehicle engines, industrial processes and wildfires), certain chemical reactions and natural sources like pollen or sea spray. PM2.5 particles are small enough to bypass the nose and throat and settle in the lungs, potentially causing respiratory diseases, heart conditions and other systemic health issues.

The smaller the particle, the deeper it can penetrate into the body. Moreover, smaller particles like PM1 stay suspended in the air longer and can travel greater distances, affecting air quality over large areas.

VOCs are a group of organic chemicals that easily evaporate into the air at room temperature. These compounds have relatively low boiling points, which allow them to transition from a liquid or solid state to a gas. They are emitted by a wide range of sources, both natural and man-made, and can significantly affect IAQ. In industrial and manufacturing settings VOCs are produced by solvents used in paints, coatings and adhesives, as well as emissions from machinery and processes involving chemicals. Cleaning agents, disinfectants and building materials are also culprits. 

Air quality monitoring systems allow you to monitor, track reports and improve the air quality in facilities. These systems enable you to ensure that the air quality in a facility meets recommended guidelines. Air quality monitoring devices help companies in any market and of any size monitor and even control their air quality to keep employees healthy, improve productivity, prevent equipment damage and downtime, and maintain manufacturing.

Camfil’s AirImage sensors measure temperature, relative humidity (RH), absolute pressure and particulate matter (PM1, PM2.5), enabling you to monitor, track and improve air quality in your facility. These user-friendly sensors are ready to use straight out of the box, offering an intuitive interface for accessing real-time and historical air quality data. With versatile connectivity, the AirImage sensors can transmit data and notifications remotely to devices connected to a building management system (BMS), the internet or a ground-penetrating radar system (GPRS). Users can easily adjust settings, view information and connect with Camfil air purifiers via the web-based user interface (UI).

The Role of Molecular Air Filters

Molecular air filters are specialized devices that remove harmful gases and odors from the air, addressing contaminants that particulate filters cannot capture. These filters are essential in environments where gaseous pollutants pose significant health risks or can damage sensitive equipment. 

In industries such as pharmaceuticals, pulp and paper mills, wastewater treatment plants, airports, museums and commercial offices molecular filters play a critical role in maintaining air purity. For instance, in healthcare, filtering out the harmful contaminant gases produced by helipads and ambulances is essential to protecting the people inside the hospital. Similarly, in manufacturing such as foam mattress or EV battery production, these filters help remove the effects of harmful gases released during production processes, ensuring a safer working environment.

Camfil’s molecular air filters remove molecules, gases and vapors from the air. They are tested according to ISO 10121 or ASHRAE 145.2. 

ISO 10121 is a series of standards that provides test methods to define the filtration efficiency of molecular air filters and filter media against various gases. ISO 10121-3, published in October 2022, is the first classification system for molecular air filters for general ventilation. It contains comprehensive filter classes for the most common air pollutants in outdoor air. This greatly facilitates the selection of the molecular filter, depending on the local outdoor air quality. 

ASHRAE 145.2 is a standard that outlines a lab test to measure how well in-duct gas-phase air-cleaning devices work. These devices use adsorption and/or chemical reactions through the use of molecular media such as activated carbon to remove harmful gases by adsorbing them or causing chemical reactions in order to bind the molecules to the media. The test is done in controlled conditions with higher gas levels than usual for ventilation systems. It’s meant to compare the performance of different devices, not to predict how they’ll perform in specific real-world settings.

Molecules are about 1,000 to 10,000 times smaller than the most minute particles that HEPA and ULPA filters can capture. Camfil molecular filters work using a process called adsorption, which means trapping gas molecules to the surfaces of molecular media to help remove gases from the air. When the entire molecular media surface is occupied, no more gas molecules can be removed.  Most of these filters use activated carbon, impregnated activated carbon or activated alumina as the key ingredient. Molecular filters are also called chemical filters or gas-phase filters.

Importance of IAQ Management and Corrosion Monitoring 

Effective IAQ management can significantly reduce corrosion rates by controlling and minimizing the presence of corrosive gaseous contaminants that accelerate material degradation. Corrosive gases, such as sulfur dioxide (SO₂), nitrogen oxides (NOₓ), hydrogen sulfide (H₂S), and chlorine, often exist in industrial and manufacturing environments. These acidic gases saturate the environment and as a result, attack expensive electronic control equipment as well as other essential operational equipment. This results in expensive maintenance costs and downtime. When these contaminants interact with moisture in the air, they form acids or other reactive compounds that attack metal surfaces, coatings and infrastructure.

Corrosion is typically not recognized until it’s too late, resulting in damage that could have been prevented. By employing IAQ management strategies, such as advanced filtration systems, climate control and real-time monitoring, facility operators can limit the concentration of these corrosive agents. For instance, high-efficiency filters can capture fine particulate matter and gaseous pollutants, while humidity control systems prevent the formation of condensation that facilitates electrochemical reactions. Furthermore, proactive monitoring allows for early detection and response to unfavorable environmental conditions, reducing the likelihood of prolonged exposure to corrosive substances. This approach not only mitigates corrosion but also supports operational efficiency and long-term sustainability.

Camfil offers solutions that integrate IAQ monitoring with corrosion prevention strategies, providing comprehensive protection for both human health and infrastructure. For example, Camfil’s AirImage-COR air quality monitor instantly measures corrosive gases in the air to indicate when users should change air filters to protect sensitive electronic equipment and preserve valuable assets. By utilizing the AirImage-COR device, industries can proactively monitor and manage corrosive elements in the air, leading to informed maintenance strategies and extended equipment lifespan.

The AirImage-COR air quality monitor features a 5-inch color touchscreen display and provides real-time International Society of Automation (ISA) standard 71.04 corrosion classification, enabling users to identify threats in real-time. It comes with a full suite of options to connect with your building management system. You can create customized email and text notifications and remotely manage the device with the progressive web application (PWA). 

Summing It Up

Integrating advanced air quality monitoring systems with corrosion management practices promotes a healthy workplace, enhances productivity and prolongs equipment life. Camfil’s solutions provide comprehensive approaches to IAQ and corrosion monitoring, ensuring safer and more efficient environments.

To discover more ways Camfil USA can help you to protect people, processes and the environment, visit us at www.camfil.us/. 

 

¹ EPA, Introduction to Indoor Air Quality, https://www.epa.gov/indoor-air-quality-iaq/introduction-indoor-air-quality

² Camfil,  PM1 – The new focus to protect human health,  https://www.camfil.com/en-us/insights/standard-and-regulations/pm1-is-most-harmful

³ Camfil, Volatile Organic Compounds Explained: FAQs Answered by Camfil Indoor Air Quality Specialists, https://cleanair.camfil.us/2024/07/17/volatile-organic-compounds-explained-faqs-answered-by-camfil-indoor-air-quality-specialists/

⁴ Camfil, ISO 10121-3:2022, https://www.camfil.com/en-us/insights/standard-and-regulations/iso-10121-3—2022

⁵ANSI/ASHRAE, Standard 145.2-2016, https://webstore.ansi.org/standards/ashrae/ansiashraestandard1452016?srsltid=AfmBOoq8I_An4gW_-h6vEaVU67Zzv15z7kpmf9HhKYA5b51sP8MglCC4

⁶ Camfil, The Importance of Molecular Air Filtration Using Carbon Filters in the U.S.: A Comprehensive Guide, https://cleanair.camfil.us/2024/04/11/the-importance-of-molecular-air-filtration-using-carbon-filters-in-the-u-s-a-comprehensive-guide/

⁷ Camfil, Gaining control over corrosion with molecular air filtration solutions, https://www.camfil.com/en/insights/electronics-and-optics/gaining-control-over-corrosion

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