Pharmaceutical Industry Gas Detection Solution

Pharmaceutical manufacturing involves numerous chemical reactions, solvent usage, and sterilization processes. During these operations, gases that are harmful to human health and the environment are inevitably generated or utilized. Substances such as hydrogen fluoride (HF), hydrogen chloride (HCl), and ethylene oxide (EO) frequently appear in laboratory synthesis, raw material handling, and finished product sterilization. These gases are highly corrosive, toxic, or carcinogenic. Once concentration control is lost or leakage occurs, they directly threaten operator health, production safety, and environmental compliance. In response to the specific needs of the pharmaceutical industry, Nexisense has developed and provides a comprehensive gas detection solution covering fixed monitoring, portable inspection, process control, and emission monitoring, helping enterprises establish a multi-layer protection system.

Gas Risk Distribution and Monitoring Priorities in the Pharmaceutical Industry

Different areas face significantly different risk characteristics and therefore require targeted monitoring strategies.

Laboratories typically conduct small-scale tests, pilot trials, and process development, involving various volatile or reactive gases with large concentration fluctuations. The focus is on process control and personnel protection. Production workshops (including synthesis, fermentation, purification, and filling sections) operate on a larger scale, with numerous pipelines, reactors, and valves, creating multiple potential leakage points. Continuous online monitoring and rapid response are essential. Warehouses store large quantities of raw materials, solvents, and intermediates. Volatile gases may accumulate slowly, requiring attention to long-term low-concentration leaks and ventilation failures. Emission outlets (the terminal points of exhaust treatment systems) are key targets for environmental regulation and must ensure compliant discharge.

The Nexisense solution covers all the above scenarios, providing diversified product combinations ranging from single-point detection to system integration, and from standard environments to extreme operating conditions.

Core Product: SGA-500 Series Fixed Gas Detector

The Nexisense SGA-500 Series Fixed Gas Detector (also known as an online gas detector) is the most commonly used basic monitoring device in pharmaceutical enterprises. The instrument utilizes original imported first-tier brand sensors. Before delivery, each unit undergoes strict debugging, integration, and calibration, requiring only a 24V DC power supply to be put into operation.

For gases commonly found in pharmaceutical environments, Nexisense provides specially optimized sensor selections to ensure sensitivity and selectivity in low concentration ranges. For example, hydrogen fluoride and hydrogen chloride sensors are specially protected against acidic corrosive gases, while ethylene oxide sensors emphasize low detection limits and anti-interference capability.

The deployment of each detector is not simply a matter of “installation.” Nexisense provides customized recommendations based on specific working conditions, including:

Optimal installation height and position (considering gas density, diffusion characteristics, and personnel activity zones)
Output signal type (4-20mA, RS485 Modbus, relay, etc.)
Cable selection and protection (corrosion-resistant, oil-resistant, high-temperature resistant)
Sampling method (diffusion type or pump suction type)
Interfacing with linked equipment (fans, valves, audible and visual alarms)

This systematic solution design significantly improves monitoring effectiveness and reliability.

Multi-Point Monitoring and Automated Response: SGA-800 Series Alarm Controller

For large pharmaceutical plants that require coverage of multiple areas or multiple gas types, a single detector cannot meet management requirements. The Nexisense SGA-800 Series Alarm Controller can network multiple SGA-500 detectors to build a centralized gas alarm system.

The controller supports multi-channel inputs and can display real-time concentration values, trend curves, and alarm status for each monitoring point. The system features multi-level alarm functions (pre-alarm, alarm, interlock) and supports linkage with workshop ventilation systems, emergency shut-off valves, and HVAC systems to achieve an automated closed loop of “detection – judgment – response.”

Through RS485 or Ethernet interfaces, the controller can also connect to existing enterprise DCS, PLC, or SIS systems, enabling data sharing and unified management. This is particularly important for data traceability and audit compliance in GMP workshops.

Emission Monitoring: Pollution Source Online Monitoring System

Pharmaceutical exhaust emissions are strictly regulated under the “Integrated Emission Standard of Air Pollutants” (GB 16297) and local regulations. Nexisense provides pollution source online monitoring systems specifically designed for exhaust outlets, incinerator flue gas, and RTO/RCO outlets.

The system can simultaneously monitor multiple parameters such as VOCs, HCl, HF, SO₂, and NOx, supporting stable sampling under high-temperature, high-humidity, and high-dust conditions. Data can be transmitted in real time via wireless or wired methods to environmental supervision platforms or enterprise control centers, facilitating compliance reporting and abnormal event traceability.

Adaptation to Extreme Working Conditions and Special Scenarios

Pharmaceutical processes often involve high-temperature, high-humidity, or dusty environments. Nexisense provides high-temperature sampling probes capable of withstanding up to 800°C for direct sampling, suitable for incinerators and oven exhaust monitoring.

For inspection needs, the SGA-600 Series Portable Gas Detector and the SGA-608 Series Handheld Multi-Parameter Gas Analyzer are ideal choices. The former is lightweight and fast in response, suitable for daily inspections and emergency troubleshooting. The latter integrates simultaneous multi-gas detection, data storage, and Bluetooth transmission, making it suitable for process validation, leak source tracing, and laboratory gas distribution assessment.

The flexible combination of these products enables enterprises to configure the most appropriate monitoring methods according to the risk characteristics of different workshops and operational stages.

Practical Value and Customer Feedback

After introducing the Nexisense gas detection system, pharmaceutical enterprises typically achieve the following improvements:

Significantly reduced risk of gas poisoning, corrosion, and explosion accidents
Enhanced employee occupational safety and reduced occupational disease hazards
Optimized operation of ventilation and exhaust treatment systems, saving energy consumption
Ensured continuous compliance of environmental emissions, reducing regulatory risks
Provided reliable process data to support process improvement and quality traceability

Practical experience from multiple pharmaceutical companies shows that after system commissioning, the occurrence rate of gas-related abnormal events has significantly decreased, environmental self-inspection compliance rates have approached 100%, and operation and maintenance costs have been effectively controlled. The professional services provided by Nexisense, including on-site surveys, solution design, installation guidance, and long-term maintenance, also save customers substantial coordination efforts.

Frequently Asked Questions (FAQ)

1. Which gases should be prioritized for monitoring in pharmaceutical workshops? Depending on the process, the highest priorities are typically hydrogen fluoride, hydrogen chloride, ethylene oxide, ammonia, hydrogen sulfide, and volatile organic compounds (VOCs). These gases are highly toxic, frequently present, and often associated with GMP critical areas.

2. How are fixed and portable detectors used differently? Fixed detectors (SGA-500) are used for continuous 24-hour online monitoring at key risk points. Portable detectors (SGA-600/608) are used for inspections, emergency troubleshooting, process validation, and temporary monitoring. They complement each other.

3. How is the installation height of detectors determined? It depends on gas density: gases heavier than air (such as chlorine, HF) should be installed at lower positions; gases lighter than air (such as ammonia) at higher positions; gases with density close to air (such as EO) at breathing zone height (1.2–1.5 meters) or near potential leak sources.

4. How many detectors can the SGA-800 alarm controller connect? Depending on the model, it supports 8, 16, 32, or more expandable channels. Large plants can network multiple controllers or use upper-level software for centralized management of hundreds of points.

5. How does the high-temperature probe ensure sensor safety at 800°C? The probe adopts special thermal insulation and cooling design to reduce the high-temperature gas to a range tolerable for the sensor, and is equipped with filtration and condensate separation components to ensure long-term stable sampling.

6. How does the system meet GMP data integrity requirements (ALCOA+)? It supports time-stamped data recording, electronic signatures, and audit trail functions. Data can be exported in tamper-proof formats and integrated with enterprise QMS systems to meet 21 CFR Part 11 requirements.

7. If a workshop already has a VOC online monitor installed, is it still necessary to install toxic gas detectors? Most VOC monitors have low or no sensitivity to inorganic acidic gases such as HF and HCl. Therefore, dedicated sensors are still required for specific highly toxic inorganic gases.

8. Does Nexisense provide complete solution design and implementation services? Yes. From risk assessment, monitoring point planning, product selection, installation, system commissioning, to training and post-maintenance, Nexisense provides one-stop services to ensure rapid project implementation and long-term stable operation.

Conclusion

Gas detection in the pharmaceutical industry safeguards the triple bottom line of safety, quality, and environmental protection. Centered on the SGA-500 Series fixed detectors and combined with the SGA-800 alarm system, pollution source online monitoring, portable instruments, and high-temperature sampling accessories, Nexisense provides comprehensive coverage for laboratories, production workshops, warehouses, and emission outlets. These products and technologies not only help enterprises effectively control gas risks but also provide data support for process optimization, energy reduction, and compliant operation. Pharmaceutical enterprises are advised to plan and implement professional gas detection systems early, based on their specific processes and risk assessments, to build a solid foundation for high-quality and sustainable development.