Compressed air is often classified as a critical utility in pharmaceutical manufacturing where it is directly involved in packaging, filling, and product handling processes. Maintaining contamination-free and moisture-free air supply is essential to meet industry quality standards. A pharmaceutical production facility reported issues related to moisture accumulation in compressed air lines which resulted in production delays and quality concerns.
Air Audit Pvt Ltd performed an on-site audit focusing on air quality parameters including pressure drop across filters and moisture levels in distribution pipelines. The analysis revealed excessive pressure loss within filtration units and inadequate drying systems which allowed moisture accumulation in downstream equipment.
Improperly maintained filters caused compressors to operate at elevated pressure levels to compensate for airflow resistance. This not only increased energy consumption but also reduced the lifespan of pneumatic components installed on production lines.
Corrective measures included installation of high-efficiency air dryers, replacement of clogged filters, and optimization of system pressure levels. These modifications resulted in improved air quality compliance and enhanced equipment performance.
Post-audit implementation enabled the facility to achieve nearly 25% reduction in compressed air system losses along with improved operational consistency.