Understanding Airlock Systems in Pharma Industry

Airlock systems are integral to various manufacturing processes, providing an effective barrier against contaminants and cross-contamination.

Rakesh Dahiya

June 25, 2023

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Understanding Airlock Systems in Pharma Industry — Airlock Systems in Pharma Industry

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Rakesh Dahiya

SDCO Cum Licensing Authority |
Food and Drugs Administration, (FDA) Haryana, India. |
Email ID: dahiya19@yahoo.com

Airlock Systems

Airlock systems play a very important role in maintaining the controlled environments and also to prevent cross-contamination in various manufacturing processes.

In this article, we will delve into the concept of airlock systems, types of airlocks e.g. sink, bubble and cascade airlocks, and discuss their applications in the manufacturing of oral solod dosage (OSD) and sterile products.

Additionally, we will also discuss the comparison between MAL (Material Airlock) and PAL (Personnel Airlock) systems, and finally, we will examine the purpose and significance of airlock systems.

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What is an Airlock System?

An airlock system is an enclosed area or cabin that acts as a transitional zone between the two different environments, typically with different levels of cleanliness or pressure.

Purpose of the airlock system is to control the flow of personnel, equipment, and materials as well as minimizing the transfer of contaminants or unwanted particles.

Types of Airlocks:

Sink Airlocks:

The Sink airlocks are designed in such a wat which maintain a unidirectional airflow and flow of air is from the cleaner area to the less clean area.

Sink airlocks are generally used in pharmaceutical manufacturing facilities for preventing the contaminants entry and also for maintaining the sterility of the manufacturing area.

The pressure inside the sink airlock is negative and positive pressure in the adjacent areas, so air travels from higher pressure area to lower pressure area.

Bubble Airlocks:

Bubble airlocks function almost similarly to sink airlocks, but with an added visual indicator.

They have provided with a transparent or translucent wall that allows staff to visually confirm if the airlock is under positive or negative pressure, ensuring proper airflow and contamination control.

The pressure inside the bubble airlock is high or positive and in adjacent sides, the pressure is less or negative.

Cascade Airlocks:

The Cascade airlocks are used in situations where there are many rooms or areas with different levels of cleanliness.

These cascade airlocks maintain a controlled pressure gradient which prevent the contaminants migration between the different areas.

The system pressure in cascade airlock increases or decreases in ascending or descending order.

Airlocks in Sterile Manufacturing and OSD Manufacturing:

Airlocks in Sterile Manufacturing:

In sterile manufacturing, maintaining a sterile environment is very important and crucial, therefore, special airlocks called sterile manufacturing airlocks are provided.

These airlocks are designed with advanced filtration systems and high level of controls for ensuring the integrity and sterility of the manufacturing process.

Airlocks in OSD (Oral Solid Dosage) Manufacturing:

OSD manufacturing airlocks are specifically designed for the production of oral solid dosage forms e.g. tablets and capsules.

These airlocks used for the transfer of materials, equipment, and personnel whereas minimizing the risk of cross-contamination and also to ensure the product quality.

Comparison: MAL vs. PAL:

Material Airlock (MAL) and Personnel Airlock (PAL) are two different types of airlocks with specific functions:

Material Airlock (MAL):

MALs are used for the transfer of materials, components and equipment between different cleanroom areas to ensure the minimal risks of contamination.

Personnel Airlock (PAL):

PALs are used to control the movement of personnel between different cleanroom areas to prevent the entry of contaminants into clean zones.

Airlock purpose:

Airlock systems serve very important purposes, including:

Contamination Control: Airlocks are used to prevent the entry of contaminants for maintaining clean environments and also to preserve integrity of the product.
Air flow and Pressure Management: Airlocks also ensure the management of pressure differentials as well as direction of airflow to ensure controlled environments and also prevent cross-contamination.
Regulatory Compliance: Airlocks play a very important and crucial role to meet out the mandatory regulatory requirements and standards of industry to maintain clean and safe environment.
Material and personnel Transfer: Airlocks used for the movement of personnel, materials and equipment to while minimize the risk of contamination.

In conclusion, Airlock systems are the integral part and used in the various manufacturing processes to provide an effective barrier to prevent the contaminants and cross-contamination.

By implementing appropriate airlock systems, the manufacturers can manufacture quality products by ensuring controlled environments and protect the integrity of their production processes.

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