With This Pump, You Increase the Efficiency of Insulin Production
In this way, the global demand for insulin can also be covered in the future
The need for insulin is steadily increasing worldwide. This demand can only be met in the future through increased production efficiency. But the challenges, as well as the demands on the systems and pumps for the production of insulin, are significant.
NETZSCH Pumps & Systems, the global specialist in complex fluid management, offers you innovative solutions for the medical and pharmaceutical industries. We will show you how to use a NEMO® progressing cavity pump to significantly increase your efficiency in insulin production while reducing your maintenance and servicing costs.
Challenge: The demand for insulin will be this high in the next few years
About 285 million people worldwide have diabetes, according to estimates by the International Diabetes Federation (IDF). According to projections, this figure will rise to 438 million by 2030. Since the first insulin analogues at the end of the 1990s, the number of preparations for diabetes therapy has grown steadily. Attempts are being made to make the mode of action more and more similar to that of natural insulin. They are mainly produced biotechnologically from recombinant DNA in various yeasts or bacteria. Numerous auxiliary substances are used here, including zinc chloride, hydrochloric acid and sodium hydroxide, which demand everything from the pumps and systems used for delivery due to their properties. In addition to the highest hygiene requirements, long service life and robustness also play a crucial role.
What to consider when choosing a pump for insulin production
For the production processes, the form of synthesis poses an enormous challenge. On the one hand, the measurement of all substances used in insulin production must be precisely adhered to achieve the desired results. On the other hand, the cell cultures used are compassionate; shear forces during the show can quickly destroy them and thus render entire batches unusable. On top of this, there are the high hygiene standards in the medical and pharmaceutical industry, which must be adhered to in every production step in the manufacture of insulin. The frequent and lengthy cleaning cycles required for this restrict productivity. Thanks to the innovative pumps and systems from NETZSCH, nothing stands in the way of gentle conveying in compliance with the strictest hygiene guidelines in insulin production.
How to sustainably increase the efficiency of insulin production
One of the leading suppliers of insulin analogues has been using unique progressing cavity pumps from NETZSCH for several years to feed the plate filters and convey cell mass and folding suspension. Regarding cleaning, the innovative pumps for insulin production were designed with a conveying chamber without dead space as far as possible. This makes the pumps easy to clean (CIP - " Cleaning-In-Place-Process") and can even be kept sterile (SIP - "Sterilisation-in-Place-Process") without having to remove them from the system. This saves you time and money.
One of the leading suppliers of insulin analogues has therefore already been using NETZSCH special hygienic progressing cavity pumps for several years to feed plate filters and convey cell mass and suspension. With a view to hygiene, the systems were specifically engineered with a conveying chamber that is as free of dead spaces as possible and designed for CIP or SIP processes. Depending on the requirement in terms of the level of hygiene, two different types of design are used, one version with a flexible rod to convey the gradient to the filters and one model with a special hygienic joint for transporting cell cultures. This pin joint is designed so that it is rinsed by the product, which means external lubrication is not needed and a build-up of residues on the joint is prevented.
On the other hand, the flexible rod transmits the rotation of the drive without any moving parts at all, which meets even higher demands for cleanliness and sterility thanks to the absence of gaps. In addition, this design is virtually maintenance-free. The first NEMO® conveyor systems were installed in insulin production in 2002 and since then additional pumps have been added on several occasions to increase capacity. In actual fact, the maintenance intervals are five years before the stator is replaced and the rotors only have to be changed after ten years.