Pharmaceutical applications - Life Science Industries

Instruments used in the Pharmaceutical Industry

Pharmaceutical manufacturing demands precision, sterility, and compliance at every stage—from active ingredient synthesis to final product testing. Processes such as hydrogenation, inhalation simulation, bioreactor gas control, and aseptic filling require accurate flow, pressure, and environmental control to ensure product quality and regulatory adherence. At Premier Control Technologies, we provide validated solutions for gas and liquid handling, clean steam systems, and critical utilities. Our portfolio includes mass flow controllers, sanitary valves, peristaltic pumps, and advanced instrumentation, all designed to meet GMP, ASME BPE, and USP Class VI standards.

Typical pharmaceutical applications

Hydrogenation

Hydrogenation is a critical step in API synthesis, requiring precise hydrogen flow and pressure control to ensure safety and consistent yield. Variations in gas delivery can compromise reaction efficiency and product purity. Maintaining stable conditions is essential for compliance with GMP and safety standards.

Relevant products:

Alicat Mass Flow Controllers – Provide multi-parameter control for hydrogen dosing with ±0.6% accuracy and fast response times. Integrated totalisers allow batch control, reducing the need for additional instrumentation.
Alicat Pressure Controllers – Maintain stable hydrogen pressure during dynamic reactions, ensuring consistent conversion rates and preventing overpressure hazards.
Key benefits:
- High accuracy for reproducible results
- Rapid response for process safety
- Digital communication for automation

Inhalation & Exhalation Simulation

Respiratory drug delivery testing requires accurate simulation of breathing patterns to validate inhalers and nebulisers. These tests replicate real-world conditions, including variable humidity and flow rates, to ensure therapeutic effectiveness.

Relevant products:

Alicat Dual-Valve Controllers – Enable bi-directional flow for inhalation/exhalation cycles, essential for realistic simulation.
Gas Composer Software – Allows precise gas blending and humidity simulation without compromising accuracy.
Key benefits:
- Accurate breath simulation
- Moisture compensation for real-world conditions
- Easy integration with automated test rigs

Bioreactor Gas Control

Biologics production relies on controlled O₂, CO₂, and N₂ delivery for cell culture growth. Maintaining precise gas ratios ensures optimal cell viability and productivity, while reducing contamination risk.

Relevant products:

Alicat BIO Series MFCs – Offer a 10,000:1 turndown ratio, eliminating the need for multiple gas lines. Designed with 316L stainless steel and USP Class VI elastomers for hygienic compliance.
CODA Coriolis Meters – Provide direct mass accuracy for liquid and gas feeds, unaffected by pressure or temperature changes.
Key benefits:
- Digital protocols for Pharma 4.0 integration
- Robust design for long-term reliability

Aseptic Filling & Dosing

Sterile filling of vials, syringes, and cartridges demands high accuracy and contamination control. Any deviation can lead to costly product loss and regulatory issues.

Relevant products:

Peristaltic Pumps (Longer dPOFLEX) – Designed for single-use tubing, reducing contamination risk and simplifying validation.
Micro-gear & Valveless Piston Pumps – Deliver ultra-precise micro-dosing for high-value formulations.
Key benefits:
- 21 CFR Part 11 compliance
- Low pulsation for accurate dosing
- Easy integration into automated filling lines

Clean Steam & Utility Pressure Control

CIP/SIP, WFI, and clean steam loops require hygienic valves to maintain sterility and prevent contamination. These systems are critical for cleaning and sterilisation in pharmaceutical plants.

Relevant products:

Steriflow Mark 96C Pressure Regulators – Self-draining design with Jorlon diaphragm for long life and cleanability.
Steriflow SSRV Safety Relief Valves – Protect fermenters and clean steam systems from overpressure.
Steriflow 978JD Control Valves – Provide precise control for sterile process applications.
Key benefits:
- ASME BPE finishes (20 Ra, electropolished)
- FDA/USP VI elastomers
- Full CIP/SIP capability

Tablet Coating & Drying

Tablet coating and drying processes require controlled airflow and humidity to ensure uniform coating and prevent degradation. Poor control can lead to uneven coating and compromised product stability.

Relevant products:

Humidity & Dew Point Sensors – Monitor compressed air and drying systems for consistent conditions.
Mass Flow Controllers – Regulate airflow for precise drying cycles.
Key benefits:
- Real-time humidity monitoring
- Stable airflow for consistent coating
- Improved process efficiency

Sterile Filtration & CIP/SIP

Filtration systems and CIP/SIP cycles demand precise pressure and flow control to maintain sterility and cleaning efficiency. Incorrect pressure can damage filters or compromise cleaning.

Relevant products:

Steriflow Sanitary Regulators – Maintain stable pressure during CIP/SIP cycles.
Alicat Pressure Controllers – Automate pressure control for filtration skids.
Key benefits:
- Hygienic design for sterile environments
- Accurate pressure control for filter integrity
- Reduced downtime during cleaning

Environmental Monitoring & Utilities

Pharmaceutical facilities must monitor cleanroom conditions, compressed air quality, and utility gases to comply with GMP. Continuous monitoring ensures product safety and regulatory compliance.

Relevant products:

Humidity & Dew Point Sensors – Ensure compressed air meets ISO 8573 standards.
Temperature & Pressure Transmitters – Provide real-time data for cleanroom and utility monitoring.
Key benefits:
- Continuous compliance monitoring
- Easy integration with SCADA/BMS
- Reduced risk of batch rejection

Lyophilisation (Freeze Drying)

Freeze drying is critical for stabilising sensitive drug products. It requires precise vacuum and temperature control to ensure product integrity.

Relevant products:

Pressure Transmitters – Monitor chamber pressure during sublimation.
Mass Flow Controllers – Control inert gas backfill for vial sealing.
Key benefits:
- Accurate pressure control for consistent drying
- Improved product stability
- Integration with automated systems

Packaging & Leak Testing

Packaging integrity is essential to maintain sterility and shelf life. Leak testing ensures container closure integrity for vials, syringes, and blister packs.

Application	Recommended Technologies	Why It Helps
Hydrogenation	Alicat MFCs & Pressure Controllers	Accurate H₂ flow & pressure control
Inhalation/Exhalation	Dual-Valve Flow Controllers	Bi-directional flow & humidity simulation
Bioreactor Gas Control	Alicat BIO Series, CODA Coriolis	Wide turndown, CIP/SIP, Pharma 4.0 ready
Aseptic Filling	Peristaltic Pumps, Micro-gear Pumps	Single-use, GMP compliance, low pulsation
Clean Steam & Utilities	Steriflow Regulators & Control Valves	ASME BPE, FDA/USP VI, self-draining designs
Tablet Coating & Drying	Humidity Sensors, MFCs	Stable airflow & humidity control
Sterile Filtration	Steriflow Regulators, Alicat PCs	Accurate pressure for filter integrity
Environmental Monitoring	Humidity, Temperature, Pressure Sensors	Continuous GMP compliance
Lyophilisation	Pressure Transmitters, MFCs	Accurate vacuum & backfill control
Packaging & Leak Testing	MFCs & Pressure Controllers	Reliable leak detection & compliance

Pharmaceutical

Instruments used in the Pharmaceutical Industry

Typical pharmaceutical applications

Hydrogenation

Relevant products:

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Inhalation & Exhalation Simulation

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Bioreactor Gas Control

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Aseptic Filling & Dosing

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Clean Steam & Utility Pressure Control

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Tablet Coating & Drying

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Sterile Filtration & CIP/SIP

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Environmental Monitoring & Utilities

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Lyophilisation (Freeze Drying)

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Packaging & Leak Testing

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Pharmaceutical Application Selection Guide

FAQs

1. Are these products GMP and ASME BPE compliant?

2. Can these devices integrate with Pharma 4.0 systems?

3. Do peristaltic pumps support single-use assemblies?

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