In the pharma manufacturing world, a clean environment is key. The materials used in critical infrastructure like ducting systems are crucial to the safety of a facility. Since this is so important, choosing the right material, such as steel, aluminium or plastic, is vital. Each has its pros and cons. In this guide we will look at these materials, their durability, cleanliness and chemical corrosion resistance and the role of metal detectable products in all of this.
The industry benchmark
Steel ducting has been the industry standard for years. The reason for this is its durability and strength. Stainless steel in particular can withstand high pressure, temperature fluctuations and mechanical stress. This makes it the go to choice for facilities where reliability and long term performance is non negotiable.
The advantages
- Durability: Steel ducting is very robust and has a life expectancy that often exceeds other materials. It’s resistant to mechanical damage so is less likely to need frequent repairs or replacements.
- Cleanliness: Its non porous surface is easy to clean and sanitise which is critical in a sterile environment. It doesn’t support bacterial or microbial growth, which is a serious concern for the industry.
- Corrosion Resistance: Stainless steel is highly corrosion resistant, even when exposed to various chemicals. This means ducting won’t degrade over time which could compromise the sterility of the environment.
- Compliance with Standards: It often meets or exceeds the strict standards required, so it is a safe and reliable choice.
But steel ducting isn’t without its downsides. One of the biggest is cost. It is more expensive than aluminium or plastic, both upfront and in installation. It is also heavier, which makes installation more complicated and requires more robust support structures.
Aluminium ducting
Compared to steel, aluminium ducting is lighter in weight and hence easy to manipulate and put in place. Another advantage is that it is also less expensive, especially useful for facilities that have limited resources in funding.
Advantages
Lightweight: Aluminium is lighter compared to other materials such as glass and stainless steel: this implies that it is easier to transport and fix, hence, less costs and time will be incurred during the installation.
Cost-Effective: In general, aluminium is cheaper than stainless steel.
Corrosion Resistance: Aluminium can resist corrosion, on some level, but is not as strong as stainless steel.
Disadvantages
Aluminium is less strong when compared to steel but lighter in weight. This flexible material is more susceptible to scratches, dents and other mechanical impacts that can harm operations. It is also a more reactive metal, especially in areas where chemical agents are frequently used and this may cause contamination in the long run.
Plastic ducting
PVC and Polypropylene plastic ducting would be the most cost efficient method. They are light in weight, very simple to install and also resistant to many chemical solutions.
Advantages
- Chemical Resistance: Some of the common types of plastics, such as PVC and Polypropylene are highly immune to a wide range of chemicals, making it appropriate for facilities that have frequent contact with corrosive chemicals.
- Cost: Among the three material choices, plastic ducting is the cheapest material, as well as installation costs.
- Flexibility: It is more flexible, which makes it easy to bend and form to other shapes and sizes making it suitable for intricate ducting plans.
Disadvantages
There are a number of drawbacks associated with plastic ducting. It is a softer and less robust material than steel or aluminium and is more vulnerable to scorching and ultraviolet radiation, as well as mechanical impacts. It is susceptible to warping or deformation in high temperature environments, thereby interfering with the efficiency of the air distribution system. Furthermore, its lack of rigidity does not create a sterile surface needed to ensure cleanliness, as it can harbour bacterias and mould if not cleaned properly.
Metal detectable products – the way forward
Whilst the ducting material can be up for discussion, the incorporation of metal detectable products during the production process is vital. When it comes to gaskets, seals and o-rings, metal detectable types are critical as they assist in eliminating the possibility of contamination by detecting foreign objects that may have found their way into the production line.
These products assist in meeting industrial standards, most of which demand proper implementation of metal detectability to enhance hygiene and safety measures. These products also mitigate the chances of having a costly shutdown resulting from cleaning or recall due to contaminants.
The best course of action
The type of construction material used for the ducting system in a pharmaceutical manufacturing facility requires careful consideration. Steel ducting proves to be highly durable and also has high cleanliness standards compared to other alternatives, hence it is ideal for facilities that require long term solutions and sterility. Aluminium is cheaper and easy to install, making it ideal for facilities that require simple installation and where costs are a major concern. The most cost-effective option is plastic ducting, but it has a lower durability and reliability factor in the long run.
Depending upon a facility’s needs for chemical exposure, temperature differences and sterility, this will guide it towards steel, aluminium or plastic options. Whichever material is utilised, incorporating metal detectable products will add additional layers of safety to the production line, ensuring a facility operates at the highest standards of compliance.