1000LPH Pharmaceutical Purified Water System Exported to Bangladesh
A newly established pharmaceutical enterprise in Bangladesh contacted Molewater to meet the GMP regulations of the Directorate General of Drug Administration (DGDA) of Bangladesh and USP standards, and solve the problems of no supporting water treatment facilities in the new factory and the need to support multiple preparation production lines simultaneously. Based on the customer’s water treatment equipment requirements, factory layout drawing, and space design needs, the engineers designed two identical 1000LPH pharmaceutical purified water systems according to the local water quality of the customer, which not only meet the full-process purified water usage requirements but also adapt to the local high-temperature and dusty operation and maintenance environment, laying a solid foundation for the smooth commissioning of the new factory.
Project challenges
High requirements for compliance and redundancy: It needs to meet both Bangladesh DGDA GMP and USP/BP standards. The commissioning of the new factory requires dual-system redundancy to avoid production suspension caused by single-system failure.
Difficulty in coordinating multiple water usage points: Production covers various water usage points, and the pipelines of the new factory need to be planned from scratch. It is necessary to avoid cross-contamination and ensure stable pressure at the water usage points.
Difficulty in adapting operation and maintenance capabilities: As a newly established enterprise, the local operation and maintenance team has limited experience. The system needs to balance automation and ease of operation, while addressing the problem of membrane pollution caused by local high-hardness raw water
Process flow
Pretreatment unit: Adopting multi-media filter to remove suspended solids and turbidity in water, activated carbon filter to adsorb residual chlorine and organic pollutants, water softener to reduce inlet water hardness and prevent scaling risks, plus a 5-micron precision filter for terminal pretreatment. This unit can extend the service life of core components.
Reverse osmosis unit: Adopting double-stage reverse osmosis + EDI configuration + UV sterilization + terminal microfiltration filter process to remove over 99% of ions and organic substances, and the produced water resistivity can reach above 15MΩ・cm. UV sterilization ensures that microbial indicators meet the standards, and terminal filtration guarantees no particulate residue in the produced water.
Circulation unit: Adopting “closed-loop pipeline + electric heating disinfection system” to avoid secondary pollution of the pipeline
Project achievements
Stable and compliant effluent: The produced water of the two systems continuously meets Bangladesh DGDA GMP and USP standards. Third-party testing shows that conductivity, TOC, microorganisms, endotoxins, and other indicators are stably within the qualified range, helping the new factory successfully pass the commissioning certification of the drug regulatory authority.
Controllable operation and maintenance costs: The system has a high degree of automation and only requires simple daily inspections. The pretreatment unit effectively extends the service life of the reverse osmosis membrane, and the annual operation and maintenance cost of a single set is 55% lower than that of local traditional equipment; meanwhile, the user-friendly design helps the operation and maintenance team of the new factory quickly master system management capabilities