Single-use filtration and fill–finish technologies can be used as part of a lean manufacturing strategy to boost production, and reduce manufacturing waste and costs.
Single-use filtration systems can deliver value in a number of ways. However, it is particularly beneficial if the single-use system has a modular structure that is replicable and scalable across different geographies, as this means the filtration assembly can keep pace with changing product, scale and site requirements.
As will be demonstrated later in a fill–finish case study, single-use assemblies can reduce processing time by as much as 50% through decreased preparation and set-up times. A number of elements drive these reductions, such as:
Before implementing single-use technologies, a thorough assessment of the current processes and opportunities for improvement should be conducted and objectives should be clearly defined. It is also important to pilot solutions and conduct performance testing in a laboratory setting before a definitive solution is finalised. Technology experts should also review process parameters, such as flow rate and pressuredrop requirements, and recommend the appropriate filter membrane and size when designing filtration subassemblies. Hands-on testing prior to installation will also give operators a greater degree of confidence than a typical new processing setup might usually foster, and will also give them the opportunity for real-time feedback, which will enable the solution to be better adapted to their actual process.