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The Next Generation of PolarisTM - What you Need to Know

Many pharmaceutical companies rely on a constant supply of water for injection and pure steam for the manufacture of parenteral drug products. As production processes have advanced, methods to produce water for injection – both hot and cold - and pure steam continue to evolve. The distillation system stands as a prime example and here at Veolia Water Technologies we are constantly seeking new ways to enhance proven technology that is trusted to work.

That is why we are launching the next generation of our PoIaris™ 2.0 range - our leading high-capacity water distillation and steam generation solutions designed for supplying hot water for injection and pure steam for manufacturers of pharmaceutical finished products. 

Distillation systems explained

Distillation Image - Cold WFI Webinar

Tried and tested, traditional distillation systems are simple in their setup and operation. Once water is fed into the system via the feed water inlet, it is heated in an evaporation chamber, turning it into steam and water mist. After this has occurred, the vapourised, gaseous substance passes through a separator, which removes any prevailing water droplets that may contain bacteria or endotoxins.

In addition, in the MED units, the produced pure steam then passes into an inclined condenser system, where it emerges as hot water for injection; a dedicated vent line will allow the removal of the non-condensable gases. 

Polaris 2.0™ – the next generation has arrived

IM_Pharma_pharmaceutical medicine industrial washer cleaning and drying machine for powder drugs glassware bottles

Though the process is simple, there are always ways these systems can be refined. The new Polaris™ 2.0 range comprises an array of standard units with different capacities, as well as several standard options to meet all requirements. 

As with all Veolia Water Technologies solutions, the next-generation Polaris™ 2.0 systems are built to last. They have been designed with simple maintenance in mind that will help to minimise downtime and costs throughout the system’s lifespan. In addition, Veolia Water Technologies offers a full suite of servicing and aftersales support including preventative and predictive maintenance to help spot and remediate issues before they arise. 

Veolia Water Technologies is also bringing the traditional distillation system into the modern era with cloud connectivity. Polaris™  2.0 models are compatible with Hubgrade, Veolia’s cloud-based remote monitoring and optimisation solution. This presents users with live operational information, alerts and advanced data analysis, which also enables faster issue resolution in collaboration with our engineers.  

Crucially, the design and construction of the Polaris™  2.0 units comply with ASME Bioprocessing Equipment (BPE) standards. In addition, for compliance with FDA CFR21 Part 11 and GAMP V, all Polaris™  2.0 units are fitted with a Siemens HMI Comfort Panel that is installed with new validated and certified software.  

Polaris MED-1

Key features of the Polaris™  2.0 MED

Designed to guarantee a steady supply of hot water for injection, the PoIaris™ 2.0 Multiple Effect Distiller (MED) units have capacities ranging from 250 to 4,500 litres per hour with a different number of columns to optimise the utilities consumption. To boost efficiency in terms of energy consumption and wastage, the Polaris™ 2.0 MED adopts a falling film distillation process to ensure high efficiency and a fast start-up. Meanwhile, the system achieves a blowdown level of just 10%, helping to minimise water waste, and the columns - with a stainless-steel frame - are also designed with ease of maintenance in mind. The system also features insulated heat exchangers and column as well as PID pressure and control.

Finally, the system is also operationally smart. Installed with a S7-1500 HMI Siemens Comfort Panel and GAMP V Validated software, users are able to monitor key metrics at all times, including water for injection temperature and conductivity.

For customers looking to add enhanced functionality, example optional features include a feed water tank, blowdown cooler, automatic feed water valve, sanitisation and automatic drain, sight glass on columns, and integration with Hubgrade for remote monitoring and assistance.

Polaris PSG-1

Key features of the Polaris™  2.0 PSG

The Polaris™ 2.0 Pure Steam Generator (PSG) provide users with a rapid-response pure steam supply which can be used for a variety of applications, including product terminal sterilisation, lyophilizer sterilisation, sterile facility HVAC humidification, and sterilisation in place (SIP) for bio reactors and vessels.   

Available in a range of sizes, the steam generators can produce between 300 and 3,000 kilograms of pure steam per hour and up to 4 barg. Quality is ensured thanks to advanced droplet separation features, as well as an integrated thermal degasser for the removal of non-condensable gases – this ensures compliance with EN285.

In addition to these standard features, which also include insulated heat exchangers and column, PID pressure and control, and an intuitive display via the S7-1500 HMI Siemens Comfort Panel, customers can select a range of optional add-ons. For instance, an extra connection can be fitted for PS testing, while Hubgrade integration makes the system compatible for remote monitoring and assistance. 

What is right for my business?

When deciding which system is right for a particular application, a number of technical considerations will need to be taken into account. From these, Veolia Water Technologies’ experts can advise on what system will best suit an operation’s needs. 

In addition to carefully scrutinising the equipment itself, weight should be given to ongoing maintenance activity. Once again, Veolia Water Technologies has a full suite of packages designed to make the upkeep of distillation systems as seamless and smart as possible – a combination of pre-planned services and real-time repairs based on data inputs via Hubgrade will significantly reduce the risk of costly downtime. 

No matter which Polaris™ 2.0 system is chosen, customers can expect to take advantage of a range of benefits designed to enhance various critical production and cleaning processes within pharmaceutical manufacturing facilities. This includes saving on water and energy through the efficient production of water for injection or pure steam, the flexibility to scale output in line with demand, and simple and smart maintenance through integration with Hubgrade. Distillation systems have stood the test of time over decades. Far from being antiquated, outdated methods of producing water for injection and pure steam, Veolia Water Technologies continues to show that the simplest methods are often the best, especially when they can be evolved and brought into the modern age.  

Interested in finding out more? Explore our water treatment solutions portfolio, product brochures, and learn more about the Polaris™ 2.0 range by consulting our experts through the button below.  

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