Solvent Safety in Pharmaceutical Manufacturing

 

The manufacture of pharmaceutical products is a complex and multi-stage operation that can include processes such as blending, wet and dry granulation, milling, hot-melt extrusion, coating, andtablet pressing. Producing the exact formulation, release rate, consistency, and dosage form requires many chemical compounds and substances.

Among the mare active pharmaceutical ingredients (API), the primary and biologically active medicinal component of the drug; excipients, the non-active components, including lipids,which serve as carriers, solubilizers, or emulsifiers of the active ingredients; and plastics or polymers used in production to create the dispensing form of the finished pharmaceutical product.

Lipids and Polymers

Lipids and polymers are vitally important to the drug production process. They are used for the fabrication of most dosage forms, release rate modifiers, enhanced drug absorption, stabilizers, solubilizers, and more.

Lipids, which are soluble in organic solvents such as ethanol, isopropyl alcohol, acetone, and benzene, are purified and refined to be used as fillers, binders, lubricants, solubilizers, emulsifiers, and emollients in a variety of delivery forms, including tablets, capsules, suppositories, emulsions, ointments, creams, and lotions.

Polymers are used in a wide variety of applications that can include everything from film coatings on medicines, to controlling the release rate of drug formulations.They are also used as a taste masking agent, stabilizer, thickener,and as a protective agent in oral drug delivery.

Solvents such as acetate, methanol, isopropanol, and ethyl acetate are used dissolve or disperse the polymer materials and apply them to the surface of the tablets and capsules.

Solvents

Solvents can be solid, liquid,or gas and are often used to dissolve, disperse, suspend, or extract other materials during pharmaceutical manufacturing. They can also be used as the medium in which the chemical reaction takes place to make APIs. To maintain a sterile environment and adhere to strict quality control standards, solvents such as isopropyl alcohol may be used to clean and disinfect surface areas and equipment.

Depending upon the manufacturing stage, the solvent being used can be either organic ( i.e., carbon-based), such as hexane, alcohols (including isopropyl, ethanol, and methanol), toluene, and acetone, among others; or inorganic solvents ( i.e., non-carbon-based), including water (the simplest and most abundant), ammonia, hydrogen fluoride, and sulfur dioxide.

Potential Safety Risks Involved with Solvent Use

While solvents are necessary components of the medicine formulation process, exposure to solvents is one of the most common hazards in the pharmaceutical production industry. Solvents can irritate the eyes and respiratory tract, cause damage to the liver, kidneys, heart, blood vessels, bone marrow, and the nervous system. Inhalation of some solvents may have a narcotic effect, causing fatigue, dizziness, unconsciousness, and even death.

Moreover, many of the organic solvents used in pharmaceutical manufacturing, such as hexane, acetone, methanol, isopropyl alcohol, ethanol, and toluene,are highly volatile, as well as flammable or combustible.

Combustible Gas Monitors Can Reduce Risk in Pharmaceutical Facilities Utilizing Solvents

Solvent vapors are very often flammable and, depending on the solvent, even explosive. It is critically important to understand the lower explosive limits (LEL) of the solvents being used, because LEL reflects the lowest concentration of gases or vapors in the air that could cause combustion in the presence of an ignition source, such as static electricity , heat, or flame.

Best practices call for combustible gas detectors to be installed in any area where flammable or combustible solvents are used or stored. In the event of a leak, and an accumulation of solvent vapors, an LEL gas detection monitor should activate visual and audible alarms, and turn on the ventilation system.

PureAire Monitors

PureAire Monitoring Systems’ line of LEL Combustible Gas Monitors is designed to meet the safety needs of pharmaceutical manufactures utilizing solvents. The Monitor is housed in a NEMA 4 explosion-proof enclosure suitable for Class 1, Groups B, C, and D, and Class 2, Groups E, F, and G. The enclosure is specifically designed to prevent an explosion. The Monitor’s durable, long-life LEL catalytic sensor will last 5+ years without needing to be replaced.

PureAire Monitors feature an easy to read screen, which displays current gas levels, for at-a-glance observation by employees, who derive peace of mind from the Monitor’s presence and reliable performance. In the event of a solvent leak, PureAire’s Monitors will set off alarms, complete with horns and flashing lights, alerting personnel to evacuate the area. Alarm signals can tie into automatic shut-off valves and ventilation systems when solvent levels reach an unsafe threshold.

Our LEL Combustible Gas monitor can connect to multi-channel controllers, a remote display, or into building systems themselves.

When Freshness Counts – Modified Atmosphere Packaging

 

Centuries ago, merchants and shippers would place a lit candle inside barrels used to store biscuits before closing the lid. The idea was that the candle flame would deplete the oxygen inside the barrel to help keep the biscuits from spoiling. These days, the candle flame has been replaced by processes called Modified Atmosphere Packaging (MAP), which can be either active or passive. By altering the atmosphere inside food product packages, or by using specialized packaging films, today’s food processors can preserve freshness and taste; extend shelf-life; prevent oxidation, which can lead to food spoilage; and protect against crushing the food contents inside the packaging, all without the use of chemical additives, stabilizers, or even candles.

Why Use Modified Atmosphere Packaging?

Consumers want food that not only looks, tastes, and smells good, but is also convenient and lasts longer than a few days after purchase. In order to satisfy consumers, food packagers need to eliminate or, at least, control factors that contribute to food spoilage, including improper levels of moisture, temperature, or light; excessive oxygen (i.e., oxidation); and the growth of microorganisms (such as mold or pathogens that can lead to food-borne illnesses).

Spoiled food means lost revenues and lower profits for producers and intermediaries, higher food prices passed on to the consumer, and an environmental burden, as food waste reportedly contributes to some 8% of global greenhouse gas emissions.

How Does MAP Work?

Active modified atmosphere packaging works by changing the atmosphere inside food packaging, typically by the introduction of gases. For instance, carbon dioxide is often used to remove oxygen from inside the packaging of breads and other baked goods, in order to keep the products from going stale, prevent mold growth, and extend shelf-life.

Packaged foods with high-fat content, such as certain cheeses or fish high in fatty acids, require a high concentration of carbon dioxide to prevent mold growth and to prevent the cheese or fish from tasting rancid. However, excessive levels of carbon dioxide can make certain foods taste sour. To prevent that from occurring, food packagers may elect to use nitrogen, or a mixture of gases, instead of carbon dioxide alone.

Conversely, while certain meat, fish, and poultry require that all or almost all oxygen be removed from inside packaging and replaced with carbon dioxide and/or nitrogen to prevent microbial growth and spoilage, oxygen is actually added to some packaged meats, low-fat fish, and shellfish to prevent fading or loss of color, as well as to inhibit the growth of certain types of bacteria.

Adding nitrogen gas to packaging not only helps salty snack foods stay crispy and fresh by displacing the oxygen inside food packaging, but it also helps protect the contents from getting crushed or broken during transport of the products from manufacturing facilities to stores and, ultimately, to consumers’ pantries.

Fresh fruits and vegetables are often packaged by using a passive form of MAP which includes specialized, permeable packaging films. The permeable film allows the fresh produce to continue to respire (that is, breathe) after being harvested, but at a much slower rate than if it were still on the plant. Low oxygen levels, combined with carbon dioxide or nitrogen, help to preserve the freshness, taste, and appearance of fresh fruits and vegetables.

Proper Monitoring Can Preserve Food Products and Protect Packaging Personnel

Balancing the correct mixture of oxygen, carbon dioxide, and nitrogen is vital when it comes to food packaging. Too much or too little of a required gas can lead to foods that have unappetizing taste, smell, or appearance and, in baked goods, can promote mold growth, and staleness.

Moreover, food packagers and others working around carbon dioxide and nitrogen need to be aware of the potential safety risks associated with these odorless and colorless oxygen-depleting gases. According to the Occupational Safety and Health Administration (OSHA), an environment in which oxygen levels fall below 19.5 percent is considered an oxygen-deficient atmosphere and should be treated as immediately dangerous to health or life. When there is not enough oxygen in the air, persons working in the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of sufficient oxygen.

Because carbon dioxide and nitrogen are devoid of odor and color, individuals working around these gases might well, in the absence of appropriate monitoring equipment, be unaware that a safety risk situation has developed.

PureAire Monitors

PureAire Monitoring Systems’ Dual Oxygen/Carbon Dioxide Monitor offers thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen and carbon dioxide levels for at-a-glance reading by food packaging employees, who derive peace of mind from the Monitor’s presence and reliable performance.

In the event of a carbon dioxide or nitrogen gas leak, and a decrease in oxygen to an unsafe level, PureAire’s Monitor will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area.

PureAire’s Dual Oxygen/Carbon Dioxide Monitor is well-suited for facilities where gases such as carbon dioxide and nitrogen are used. Our Dual O₂/CO₂ monitor includes both a non-depleting, zirconium oxide sensor cell, to monitor oxygen levels, and a non-dispersive infrared (NDIR) sensor cell, to monitor carbon dioxide levels. PureAire’s O₂/CO₂ monitors can last, trouble-free, for over 10 years under normal operating conditions.

Safe Use of Liquid Nitrogen in Food Processing Plants

 

In December 2020,  two employees working at a Vernon, California food processing plant lost consciousness and died following an apparent liquid nitrogen leak. On January 28, 2021, there were several fatalities, and many other employees became sick, after being exposed to nitrogen gas when a liquid nitrogen line ruptured at a food processing plant in Gainesville, Georgia.According to the Occupational Safety and Health Administration (OSHA), a total of fourteen workers died from asphyxiation linked to nitrogen gas in twelve separate workplace accidents recorded between 2012 and 2020, and 2021 is already off to a sad start.  Tragically, these accidents illustrate the dangers of working with liquid nitrogen.

Importance of Liquid Nitrogen in Food Processing

Liquid nitrogen (LN2) is used in food processing in a number of applications, including grinding, mixing, coating, freezing, and packaging foods. Food processors may use liquid nitrogen in the production of a variety of foods, such as meat, poultry, seafood, fruits, vegetables, baked goods, and prepackaged meals. The very low temperature of LN2 is used to flash-freeze foods to help prevent microbial growth that can lead to food spoilage, and to maintain the foods’ original freshness, flavor, and textures.

Oxygen Monitors Can Reduce the Risk of Liquid Nitrogen Accidents

While the use of liquid nitrogen is important in food processing, it is not without risk. When liquid nitrogen is exposed to the air (which happens when leaks occur), it will evaporate, changing from a liquid to an oxygen-depleting gas. Oxygen deprivation can put employees in real danger if there are leaks from pressurized LN2 freezer lines, exhaust systems, or on-site storage containers. In the event of a liquid nitrogen leak, food processing workers could become disoriented, lose consciousness, or even suffocate from breathing oxygen-deficient air. Since LN2 is both odorless and colorless, workers would, in the absence of appropriate monitoring, have no way of knowing that there has been a liquid nitrogen leak.

However, by utilizing a top-quality oxygen deficiency monitor, food plant personnel can safely track oxygen levels and detect leaks before workers’ health is jeopardized.Best practice calls for oxygen deficiency monitors to be installed anywhere there is a risk of liquid nitrogen gas leaks. The monitor should be placed wherever liquid nitrogen is stored, and in all areas where liquid nitrogen is used. The monitoring equipment should include visual and audible alarms that would be activated in the event of liquid nitrogen leaks and a decrease in oxygen levels.

PureAire Monitors

PureAire Monitoring Systems’ line of oxygen deficiency monitors, including a water-resistant unit for facilities requiring daily wash-downs, offers thorough air monitoring, with no time-consuming maintenance or calibration required. In the event of a liquid nitrogen leak, and a decrease in oxygen to an unsafe level, PureAire’s oxygen deficiency monitor will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area. PureAire oxygen deficiency monitors are ideally suited for use in food processing facilities because the monitors can withstand temperatures as low as -40 Celsius. Each PureAire O2 monitor has an easy to read screen, which displays current oxygen levels, for at-a-glance reading by food processing employees, who derive peace of mind from the monitor’s presence and reliable performance.

Air Delivery of Super-Cooled COVID-19 Vaccines

There are several potential COVID-19 vaccines that may soon be available for widespread distribution. In particular, the United Kingdom has recently approved Pfizer’s vaccine, and the U.S. Food and Drug Administration is considering extending Emergency Use Authorization to the Pfizer and Moderna vaccines.

That is certainly promising news, but storage, transportation, and delivery of these potentially game-changing vaccines will be quite challenging, with the CEO of the International Air Transport Association describing the distribution of COVID-19 vaccines as “the largest and most complex logistical exercise ever” undertaken.

It is not just the huge numbers (literally, in the billions of doses) and vast geographic scope (worldwide, requiring delivery to every country on the planet) that make the COVID-19 vaccine distribution task so daunting, but both the Pfizer and Moderna vaccines must be stored and transported in strict climate-controlled environments (reportedly, at some -70 degrees Celsius for Pfizer, and -20 degrees Celsius for Moderna) as integral parts of the vaccines’ “cold chains.”

COVID-19 Vaccine Cold Chain

The U.S. Centers for Disease Control (the “CDC”) describes a cold chain as a temperature-controlled supply chain that includes all vaccine-related equipment and procedures. The vaccine cold chain begins with a cold storage unit at the vaccine manufacturing plant, extends to the transport and delivery of the vaccine (including proper storage at the provider facility), and ends with the administration of the vaccine to the patient. A breakdown in protocols anywhere along the cold chain could reduce the effectiveness of, or even destroy, a vaccine.

Given the extreme cold temperatures required within their cold chains by the Pfizer and Moderna vaccines (and, perhaps, other COVID-19 vaccines that may now be under development by other firms), various companies within the vaccine delivery network (including temperature-controlled container manufacturers, logistics specialists, storage facility operators, commercial airlines, and dry ice producers) have been hard at work for months to meet the challenges associated with safely storing and transporting billions of vaccine doses once, as now appears to be at hand, they finally become available for international distribution.

Creating Super-Cold Environments

Dry ice, which is the common name for solid (i.e., frozen) carbon dioxide, is often used in cold chains to maintain the very cold temperatures required to keep certain vaccines viable. At a temperature of approximately -78.5 degrees Celsius (equating to -109.3 degrees Fahrenheit), dry ice is significantly colder than frozen water (that is, conventional ice), making it ideal for transport and storage of those vaccines which require an extremely cold temperature environment.

Safety precautions are critical when shippers use dry ice in the transportation and storage of vaccines. Unlike conventional ice, dry ice does not melt into a liquid. Instead, dry ice “sublimates” (changes from a solid to a gas state), turning into carbon dioxide gas. In poorly ventilated, confined spaces, such as storage rooms, railway cars, trucks, and cargo holds in airplanes, carbon dioxide can build up, creating a potentially serious health risk to transportation workers, including ground and flight crews.

Certain vaccine manufacturers may elect to ship their vaccines in multi-layered, storage canisters chilled with liquid nitrogen, rather than dry ice. We note that the potential health risks associated with nitrogen leaks are similar to those that may be caused by dry ice sublimation.

Oxygen Deficiency Risks Associated with Super-Cooled Environments

Carbon dioxide (as is nitrogen) is an oxygen-depleting gas that is both odorless and colorless. As such, absent appropriate monitoring, personnel working with the transportation of COVID-19 and other vaccines kept frozen with dry ice or liquid nitrogen likely would be unable to detect if dry ice were to sublimate (causing CO2 levels to rise), or if there were a nitrogen gas leak, and an associated decrease in oxygen.

According to the Occupational Safety and Health Administration (OSHA), an environment in which oxygen levels fall below 19.5 percent is considered an oxygen-deficient atmosphere and should be treated as immediately dangerous to health or life. When there is not enough oxygen in the air, persons working in the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of sufficient oxygen.

FAA Guidance/Increased Air Shipment Capacity/Risk Mitigation

On May 22, 2009, the U.S. Federal Aviation Administration (the “FAA”) issued Advisory Circular No. 91-76A to specifically address the risks associated with the sublimation of dry ice aboard aircraft and, historically, the FAA has permitted even widebody aircraft to carry only relatively small amounts (typically not exceeding 1-1.5 tons per flight) of dry ice in refrigerated and insulated containers.

However, The Wall Street Journal (the “WSJ”) reported on November 29, 2020, that, in order to maintain the ultra-cold temperatures required by Pfizer’s COVID-19 vaccine, United Airlines has recently sought, and obtained, FAA approval to carry up to 15, 000 pounds (7.5 tons) of dry ice per flight. In a December 2, 2020 interview with CNN, Josh Earnest, Chief Communications Officer with United Airlines, noted that the FAA approval will allow United to ship as many as 1.1 million doses of COVID-19 vaccines on each flight of its commercial 777 airplanes.

Notwithstanding the FAA’s relaxation of dry ice weight limits to permit United Airlines to help bring the COVID-19 pandemic under control, it remains focused on risks associated with air shipments of dry ice. In its November 29, 2020 reporting, the WSJ noted that “regulators restrict the amount of dry ice that can be carried on passenger jets because they typically lack the equipment to monitor and mitigate any leaked carbon dioxide.”

Fortunately, by utilizing a top-quality oxygen-deficiency monitor, vaccine storage and transportation personnel, including flight crews, can safely track levels of oxygen and detect (and react to) potentially dangerous low oxygen levels, whether caused by dry ice sublimation or a nitrogen gas leak.

PureAire Monitoring Systems, Inc.

PureAire Monitoring Systems’ Oxygen Deficiency Monitor offers thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen levels, for at-a-glance reading by crew members, who derive peace of mind from the Monitor’s presence and reliable performance.

Built with zirconium oxide sensor cells, to ensure longevity, the Monitor can last, trouble-free for 10 years in normal working conditions.

Our Oxygen Deficiency Monitor does not rely on the partial pressure of oxygen to operate, meaning that the Monitor is not affected by the changing pressure inside an aircraft due to altitude changes. In the event that dry ice begins to sublimate (causing carbon dioxide levels to rise), or if there is a nitrogen leak, and oxygen decreases to unsafe levels, PureAire’s Monitor will set off an alarm, complete with horns and flashing lights, alerting flight personnel to take corrective action.

For over 20 years, PureAire Monitoring Systems has been an industry leader in manufacturing long-lasting, accurate, and reliable Oxygen Deficiency Monitors. We have dedicated ourselves to ensuring the safety and satisfaction of our clients, many of which have very sophisticated operating requirements. We are proud to note that NASA’s SOFIA-Stratospheric Observatory for Infrared Astronomy--a Boeing 747SP aircraft modified to carry a 2.7 meter (106 inch) reflecting telescope--carries onboard a PureAire Oxygen Deficiency Monitor.

What are Oxygen Deficiency Monitors?

What is an Oxygen Deficient Environment?

The Occupational Safety and Health Administration (OSHA) defines an environment in which oxygen levels fall below 19.5 percent as an oxygen-deficient atmosphere, which should be treated as immediately dangerous to health or life. When there is not enough oxygen in the air, persons within the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of sufficient oxygen.

An oxygen-deficient environment may be created when oxygen is displaced by inert gases, such as nitrogen, helium, argon, or carbon dioxide. Therefore, manufacturers and other organizations utilizing inert gases in their operations need to successfully navigate complex working environments in which high concentrations of such gases may be critical to production procedures, but where the risks of oxygen deficiency may pose a potential safety hazard for their employees.

Fortunately, by utilizing a top-quality oxygen deficiency monitor, facility managers can maintain stringent processing requirements, as well as protect the health and safety of their personnel.

What is an Oxygen Deficiency Monitor?

An oxygen deficiency monitor is a device that measures oxygen levels in a particular area. By continuously tracking oxygen levels, oxygen deficiency monitors are designed to detect gas leaks from oxygen-depleting gases before employee health is jeopardized.

A number of gases, including nitrogen, helium, carbon dioxide, and argon, among others, are odorless, colorless, oxygen-depleting gases. As such, unless they are using a reliable oxygen deficiency monitor, personnel would likely be unable to detect a gas leak should one occur in a gas cylinder or line.

Which Industries Should Use Oxygen Deficiency Monitors?

Oxygen deficiency monitors contribute to safe working environments in any scientific or industrial application utilizing oxygen-depleting gases and, therefore, requiring continuous monitoring of oxygen levels. For instance:

• The medical industry uses inert gases for a variety of purposes, including MRI facilities, performing cryosurgery, in-vitro fertilization, and cryostorage facilities, and for blood and tissue preservation, while laboratories typically use compressed gases including argon, nitrogen, and carbon dioxide.
• Pharmaceutical manufacturers depend upon gases such as nitrogen and carbon dioxide to maintain sterile environments throughout the drug manufacturing and packaging processes.
• The food and beverage industries rely on carbon dioxide and nitrogen gas for a range of uses. By way of example, carbon dioxide carbonates beverages in bars, fast-food establishments, and restaurants, and it is a critical component in the productions of soft drinks and beer. Nitrogen gas is important in food preservation processes, where it is used to remove oxygen from the manufacturing environment, extend product shelf life, and decrease the likelihood of spoilage.
• Semiconductor fabricators and foundries must closely monitor process gas levels, as an improper amount of gas can ruin the quality and integrity of the components and devices being manufactured.

The foregoing bullet points highlight just a few of the industries that need oxygen deficiency monitors as part of their daily operations. Others include aerospace, cryotherapy, additive manufacturing, research and development, alternative fuel, waste management, and the oil and gas sectors.

PureAire Oxygen Deficiency Monitors

PureAire Monitoring Systems’ line of oxygen deficiency monitors offer thorough air monitoring, with no time-consuming maintenance or calibration required. Our monitor continuously tracks oxygen levels and, in the event of a gas leak and a drop in oxygen to an OSHA action level, will set off an alarm, complete with horns and flashing lights, alerting employees to evacuate the affected area.

The monitor will remain accurate at temperatures as low as -40C. PureAire’s durable, non-depleting, long-life zirconium oxide sensor will last for 10+ years in a normal environment without needing to be replaced.

Where Should Oxygen Deficiency  Monitors Be Installed?

Oxygen deficiency monitors should be installed 3 to 5 feet away from a gas cylinder or gas line, and in any location where there is a risk of gas leaks that may cause a drop in oxygen to an unsafe level.  So that employees can see the monitors and verify their performance, the monitors should typically be mounted 3 to 5 feet off the ground.

There are many other configurations for mounting. For instance, PureAire oxygen deficiency monitors can sample oxygen levels from up to 100 feet away using ¼  inch tubing, or be installed within a glovebox, freezer, gas line, sealed chamber, or even below ground level. PureAire oxygen deficiency sensors can be mounted directly in vacuum chambers with the use of a KF25 vacuum fitting.

How Many Oxygen Deficiency Monitors Do I need?

To ensure safety, PureAire generally recommends that one monitor be installed for approximately every 400 square feet of your facility’s space. However, since cryogenic gases, such as argon, helium, and nitrogen, are unpredictable, we encourage you to contact PureAire for additional guidance specific to your needs.

Don't Throw Away Your Shot...the Cold Truth About Vaccine Handling and Storage

 

In modern times, vaccines have been widely used to keep people healthy by protecting them from serious illnesses and diseases. Worldwide, vaccines annually prevent millions of deaths, and their utilization is responsible, in many parts of the globe, for the nearly total eradication of numerous diseases, including polio, measles, and smallpox.

According to the U.S. Centers for Disease Control (the "CDC"), a vaccine for a specific disease stimulates an individual's immune system, causing it to produce antibodies to counteract the antigens associated with the disease in question, just as one's immune system would do if one were actually exposed to the disease. The concept is that, after getting vaccinated, the inoculated patient develops immunity to the disease without first having to contract it. Unlike medicines, which are used to treat or cure diseases, vaccines are intended to prevent them.

Handling and Storage of Vaccines

Developing a vaccine can take years before it is deemed safe for human use and, thereafter, manufactured and made available for widespread distribution and inoculation. Throughout the manufacturing and  distribution process, and up to the time of administration, a vaccine must be kept in strict climate-controlled environments, collectively referred to as the "cold chain." The CDC describes a cold chain as a temperature-controlled supply chain that includes all vaccine-related equipment and procedures. The vaccine cold chain begins with a cold storage unit at the vaccine manufacturing plant, extends to the transport and delivery of the vaccine (including proper storage at the provider facility), and ends with the administration of the vaccine to the patient. A breakdown in protocols anywhere along the cold chain could reduce the effectiveness of, or even destroy, a vaccine.

According to FedEx, while most vaccines have traditionally been transported in a cold temperature range of 2 degrees Celsius to 8 degrees Celsius, certain vaccine manufacturers and pharmaceutical firms require a much lower temperature range within the cold chain associated with specific vaccine products.

Dry ice, which is the common name for solid (i.e., frozen) carbon dioxide, is often used in cold chains to maintain the very cold temperatures required to keep certain vaccines viable. At a temperature of approximately -78.5 degrees Celsius (equating to  -109.3 degrees Fahrenheit), dry ice is significantly colder than frozen water (that is, conventional ice), making it ideal for transport and storage of those vaccines requiring an extremely cold temperature environment.

Safely Tracking Carbon Dioxide Levels When Working with Dry Ice

Safety precautions are critical when shippers use dry ice in the transportation and storage of vaccines. Unlike conventional ice, dry ice does not melt into a liquid. Instead,  dry ice "sublimates" (changes from a solid to a gas state), turning into carbon dioxide gas. In small, poorly ventilated spaces, such as storage rooms and closets, cargo vans, trucks, and airplanes, carbon dioxide can build up, creating a potentially serious health risk.

Carbon dioxide is an oxygen-depleting gas that is both odorless and colorless. As such, absent appropriate monitoring, workers involved with the transportation and/or storage of products frozen with dry ice likely would be unable to detect if dry ice were to begin to sublimate, with carbon dioxide gas levels possibly rising to unsafe levels. When there is not enough oxygen in the air, persons working in the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of oxygen

Fortunately, by utilizing a top-quality oxygen monitor, also known as an oxygen deficiency monitor, vaccine transportation storage personnel can track oxygen levels and detect (and react to) dangerous carbon dioxide levels before employee health is jeopardized.

PureAire Dual Oxygen/Carbon Dioxide Monitor

PureAire Monitoring Systems' Dual Oxygen/Carbon Dioxide Monitor offers thorough air monitoring, with no time-consuming maintenance or calibration required.  A screen displays current oxygen and carbon dioxide levels, for at-a-glance reading by employees, who derive peace of mind from the Monitor's presence and reliable performance.

In the event that dry ice begins to sublimate, causing carbon dioxide levels to rise, and oxygen to decrease to unsafe levels, PureAire's Monitor will set off an alarm, complete with horns and flashing lights, alerting personnel to evacuate the area.

Our Dual Oxygen/Carbon Dioxide Monitor is well-suited for industries where dry ice is used, such as in the handling, transportation, and storage of life-saving vaccines. The Monitor includes both a non-depleting, zirconium oxide sensor cell, to monitor oxygen levels, and a non-dispersive infrared (NDIR) sensor cell, to monitor carbon dioxide levels. Known for their dependability, PureAire's O2/CO2 Monitors can last, trouble-free, for over 10 years under normal operating conditions.

Brewers Safely Capture and Reuse Carbon Dioxide

 

Brewing beer produces carbon dioxide (CO₂), especially during fermentation (the process by which yeast converts sugars into alcohol). Estimates are that fermentation yields three times as much carbon dioxide as is actually needed to produce (including brewing, canning, and bottling) each batch of beer, with up to 15 grams of CO₂ generated per pint of beer brewed. According to the British Beer & Pub Association, over 8 billion pints of beer were consumed in the United Kingdom alone in 2019, contributing to the production of a whole lot of carbon dioxide.

While large, global breweries, with their vast financial resources, have been recapturing and reusing carbon dioxide for a number of years, most craft brewers have considered carbon recapture technology to be prohibitively expensive. They have treated excess CO₂ as waste, and vented it into the atmosphere, though that practice may make little sense, either economically or environmentally since, in order to produce subsequent batches, brewers must then turn around and purchase carbon dioxide to carbonate the beer, purge beer tanks and lines of oxygen, and to transfer the beer from tanks to bottles or cans.

And carbon dioxide purchase is a recurring line-item expense that eats into craft brewers’ profit margins.

Capturing and Reusing Carbon Dioxide

The good news is that recent technological innovations, driven in large part by companies working with NASA on space exploration and investigation, have led entrepreneurs to an awareness that CO₂ recapture may in fact now be seen as a relatively affordable, and certainly environmentally friendly, option for craft breweries. The technology involves capturing the CO₂ that has accumulated during fermentation and purifying the gas to make it suitable for reuse and/or sale.

The Washington Post has reported that Texas-based Earthly Labs has created a product called “CiCi” (for “carbon capture”), a refrigerator-sized unit that enables brewers to trap and reuse accumulated carbon dioxide. Captured CO₂ is piped from the fermentation tanks to a “dryer” to separate water from CO₂gas. The gas is next purified and chilled to a liquid for ease of storage and subsequent use.

Brewers can reuse their stored carbon dioxide to carbonate new batches of beer, as well as in the canning and bottling processes for the new beer. Craft Brewing Business, a trade website dedicated to the business of commercial craft brewing, reports that breweries can reduce monthly carbon dioxide expenses by 50 percent or more, and CO₂ emissions by up to 50%, via carbon capture technology.

Breweries that capture more CO₂ than they can use, may elect to sell the surplus to other breweries, bars, restaurants, and any other businesses that also use carbon dioxide. For instance, the State of Colorado, Earthly Labs, the Denver Beer Co., and The Clinic announced in early 2020 a pilot program in which Denver Beer Co. would sell its surplus CO₂ to The Clinic, a medical and recreational cannabis dispensary, which would then pump the carbon dioxide inside its grow rooms to stimulate and enrich plant growth.

Oxygen Monitors Can Mitigate Unseen Dangers of Carbon Dioxide

Brewers and others working around carbon dioxide need to be aware of the potential risks associated with CO₂. Carbon dioxide is an odorless and colorless oxygen-depleting gas. Since it deprives the air of oxygen, CO₂ use presents a potential health hazard for brewery personnel.

According to the Occupational Safety and Health Administration (OSHA), an environment in which oxygen levels fall below 19.5 percent is considered an oxygen-deficient atmosphere and should be treated as immediately dangerous to health or life. When there is not enough oxygen in the air, persons working in the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of sufficient oxygen. Because CO₂ is devoid of odor and color, individuals working around it might well, in the absence of appropriate monitoring equipment, be unaware that a risk situation has developed.

As such, The National Fire Protection Association recommends that gas monitoring equipment be placed in storage areas or any place where carbon dioxide is used or stored.

PureAire Dual O₂/CO₂ Monitors

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PureAire Monitoring Systems’ Dual Oxygen/Carbon Dioxide Monitor offers thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen and carbon dioxide levels for at-a-glance reading by brewery employees, who derive peace of mind from the Monitor’s presence and reliable performance.

In the event of a carbon dioxide leak, and a decrease in oxygen to an unsafe level, PureAire’s Monitor will set off an alarm, complete with horns and flashing lights, alerting brewery personnel to evacuate the area.

PureAire’s Dual Oxygen/Carbon Dioxide Monitor is well-suited for facilities where carbon dioxide is used, such as breweries, bars, and restaurants. Our Dual O₂/CO₂ monitor includes both a non-depleting, zirconium oxide sensor cell, to monitor oxygen levels, and a non-dispersive infrared (NDIR) sensor cell, to monitor carbon dioxide levels. PureAire’s O₂/CO₂ monitors can last, trouble-free, for over 10 years under normal operating conditions.

Saving money, reducing greenhouse gas emissions, and ensuring employee safety...that is certainly something to which we can all raise a glass.