In bioprocess industries, foaming is a major technological issue as it could cause an undesirable side effect on the process. Therefore, it needs to be detected and controlled in a best way possible.

The understanding of ‘foam’ is simple as we can find it in our day to day life in milkshake, bath foam etc., but practically it has more complex structure when it comes to bioprocess industries.

The precise and reliable methods of measuring & controlling of foam can directly contribute to improvement of product quality & yield and thereby lessen the overhead cost. 

Foam control is done by addition of anti-foaming agents, which improve process control, increase in efficiency.

The problem of foam formation varies according to the type of industry and adversely affects the productivity. It causes serious difficulties in the areas of pharmaceutical, food & beverage, waste water, chemical treatment plants etc.

Generation of Foam and its Impact on Pharmaceutical Process

The pharmaceutical Industry uses fermenters for production and involves stirring and mixing of air and gas for operation. However, these natural organisms create unwanted bi-products which support foam stabilization making it easy for stable foam production. There are the chances of liquid completely turning into foam if not controlled on time.

If left unchecked, foam can: 

• Occupy valuable reactor space, hence reduce productivity 

• Chances of foam entering in pipe lines and causing damage to pumps and sensors  

• Increases down time 

• Reduces overall process efficiency and hence heavy cost 

• Degradation of quality of final product due to excess foam or anti foam agent. 

• Increase the wastage and environmental pollution 

Challenges in Foam Measurement

• It is difficult to carry out level measurement of foam level and foam-liquid interfaces
• The performance can be affected by different factors including frequent change in the density of foam and gradual layering or fouling of the instruments due to by-products left in the bioprocess.
• Delayed sensing of level instrument decline the accuracy of measurement & control techniques

Smart Solution for Foam Control

Techtrol Foam Detector ‘Suresense’ uses the patented IMA Sensing® technology developed by Hycontrol.  It  offers advanced solution in foam monitoring and control. 

• Sensors differentiates between actual foam and residual deposits of foam and product that build up  on the sensor. 
• Provides reliable performance even when the probe is heavily coated with dense and sticky layers  
• Provides o/p of 4?20 mA corresponding to foam level/density which helps for monitoring and control  foam automatically.
• Enables precise dosing of anti?foaming agents reducing chemical usage and improve process  efficiency

Environmental and Economic Benefits

Detection of foam during process and its control helps to:  

• Minimize overuse of anti?foam chemicals 
• Reduce product loss and improves yield 
• Cuts operational costs and downtime 
• Supports sustainable practices by lowering chemical waste 

Conclusion

Across the globe, companies are spending billions of dollars every year to deal with foam problem and its effects on their business. Foam control using advanced foam detection system can enhance efficiency, reduce cost, and protect both product integrity and the environment.

There are many examples which show that considerable cost reduction can be achieved by pro-actively controlling the foaming problem by using foam detectors.