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Internship Report Talha Internee
Internship Report Talha Internee
“Internship Report”
Penicillin Plant
Citi Pharma Limited
Submitted by:
Name: Talha Waheed
Department: Department of Chemical Engineering
University: University of Gujrat (Hafiz Hayat campus)
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Dedication:
I dedicate this report to:
To All My Teachers:
Whose guidance and mentorship have been invaluable throughout my academic journey.
Your unwavering support has shaped my understanding and fueled my passion for the
pharmaceutical industry.
My Parents:
For your constant encouragement, understanding, and belief in my abilities. Your love and
support have been the pillars of my success, and I am grateful for the sacrifices you've made to
see me achieve my goals.
Duration:
“16 Feburary to 29 Feburary, 2024”
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Acknowledgment:
In the name of Allah, the Most Gracious, the Most Merciful. I am profoundly grateful
to Allah Almighty for His unwavering guidance, blessings, and grace throughout my internship
journey. His infinite wisdom has been a guiding light, providing me with strength, resilience, and
clarity in every step of this learning experience.
May Allah's blessings be upon them and all those who have contributed to my growth
and learning journey.
“List Of Contents”
• Introduction………………………………………………………………………………05
➢ Introduction and overview of the industry………….…………..05
➢ Introduction of Penicillin………………..………………….…..06
• Raw Materials……………………………………………………………………………07
• Chemical Reaction…………………………………………………………………...…..08
• Process flow Diagram……………………………………………………………………09
• Block Diagram………………………………………………………………………...…09
• Unit Processes………………………………………………………………..…………..09
➢ Chemical Reactions……………………………………….....10
➢ Crystallization………………………………………………..14
• Unit Operations…………………………………………………………………………..16
➢ Centrifugation………………………………………………..16
o Recovery of IPA…………………………………………17
➢ Smashing…………………………………………………….17
➢ Drying…………………………………………………..........18
➢ Compaction or …………………………………………….....18
➢ micronization………………………………………………...19
➢ Cone Blender……………………………………………...…19
➢ Metal Detection………………………………………………20
➢ Storage and Transport………………………………………..21
• Uses Of Penicillin……………………………………………………...……………...…22
• Suggestions for Improvement………………………………………………………....…23
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Abstract:
This report outlines the enzymatic synthesis of penicillin, focusing on key processes such
as raw material preparation, chemical reactions, and unit ope rations like centrifugation,
smashing, and drying. It discusses the use of cutting-edge techniques for quality control and
proposes improvements for enhanced efficiency in penicillin production. This comprehensive
analysis offers valuable insights into pharmaceutical manufacturing practices, paving the way for
future advancements in antibiotic production.
Core Values:
At the heart of Citi Pharma's success are its core values—Honesty, Integrity, Respect,
Excellence, Passion, Work-life Balance, and Ownership. Upholding the highest ethical
standards, every employee at Citi Pharma is driven by a commitment to integrity, ensuring that
regulations and procedures are steadfastly followed to produce pharmaceutical products of the
utmost quality.
Commitment to Quality:
Citi Pharma's state-of-the-art manufacturing facilities are strategically designed to ensure
a steadfast commitment to quality at every stage of the production process. The company
functions as a cohesive team, working tirelessly to guarantee that customers can rely on Citi
Pharma for the highest quality medicines.
improving the overall quality of healthcare, and this commitment is evident in its innovative
thinking and dedication to out-of-the-box solutions.
Introduction of Penicillin
History:
Penicillin, the first antibiotic, was discovered by Alexander Fleming in 1928. Its
development by Howard Florey and Ernst Chain in the 1940s revolutionized medicine, saving
countless lives, especially during World War II. Penicillin's discovery paved the way for modern
antibiotics, significantly reducing mortality rates from bacterial infections.
Basics:
Penicillin is a group of antibiotics that are derived from Penicillium fungi. It was the
first antibiotic discovered and is widely used to treat various bacterial infections. The discovery
of penicillin revolutionized medicine and has saved countless lives since its introduction.
Working:
Penicillin works by interfering with the ability of bacteria to synthesize cell walls,
leading to their weakening and eventual destruction. This makes it effective against a wide range
of bacterial infections, including streptococcal infections, staphylococcal infections, and
pneumococcal infections, among others.
Types:
There are several types of penicillin antibiotics, including penicillin G, penicillin V,
amoxicillin, and ampicillin, each with its own spectrum of activity and clinical uses. Penicillin is
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typically administered orally or via injection, depending on the type of infection being treated
and the severity of the illness.
While penicillin is highly effective against many bacterial infections, some bacteria
have developed resistance to it over time. This has led to the development of other antibiotics to
combat these resistant strains. However, penicillin remains an essential tool in the fight against
bacterial infections and continues to be widely prescribed by healthcare providers around the
world.
“Raw Materials”
Methyl Ester:
The methyl ester, which is likely derived from p-hydroxyphenylglycine (PHPG)
through esterification, is another important reactant in the synthesis of amoxicillin. It reacts with
6-APA under enzymatic catalysis to form the side chain of amoxicillin, completing the synthesis
of the antibiotic molecule. The methyl ester provides the necessary functional group to confer
specific properties and activities to the final product.
Above I have provided an initial explanation of the two major reactants involved in
the enzymatic synthesis of amoxicillin: 6-APA and Methyl Ester. Further details regarding their
usage in specific steps of the synthesis process will be explained as we delve into each stage.
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Chemical Reaction:
Here are the reactions involved in the enzymatic synthesis of amoxicillin:
6-APA+PHPGME→Amoxicillin+Side Products
C8H11NO2S+C10H13NO3→C16H19N3O5S+Side Products
These are the primary reactions involved in the enzymatic synthesis of amoxicillin. The
first reaction represents the synthesis of amoxicillin from its precursor molecules, while the
second reaction involves the hydrolysis of Penicillin G to produce 6-APA, one of the key starting
materials for amoxicillin synthesis.
The second reaction provided is not directly related to the synthesis of amoxicillin. It
depicts the enzymatic hydrolysis of penicillin G (Pen G) into 6-APA, which is one of the raw
materials used in the synthesis of amoxicillin. Here's the reaction:
Let’s begins with a comprehensive process flow diagram outlining the sequential steps
involved in the production of amoxicillin. This is followed by detailed block diagrams focusing
on specific units or operations within the process, providing a deeper insight into their
functionality and interactions.
Block Diagram
Unit Process
“Glycol”
Glycol(cooling agent):
In the jacketed reactor where glycol is utilized as a cooling agent, it serves a vital role in
maintaining optimal temperature conditions for the reactions occurring within the vessel. Here's
an explanation of how glycol functions as a cooling agent:
Temperature Control:
As the reaction proceeds, heat is generated or absorbed depending on the exothermic or
endothermic nature of the reaction. The glycol circulating in the jacket absorbs excess heat from
the reaction mixture, preventing temperature spikes and ensuring that the reaction proceeds at the
desired temperature range.
Cooling Efficiency:
Glycol has excellent thermal properties, including high specific heat capacity and
thermal conductivity, making it an efficient cooling agent. It effectively absorbs heat from the
reactor vessel, allowing for precise temperature control within the desired operating range.
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Temperature Stability:
By regulating the temperature using glycol as a cooling agent, the reaction conditions
remain stable and consistent, promoting reproducibility and enhancing the efficiency of the
chemical process. This stability is crucial for achieving the desired reaction kinetics and product
quality.
Safety Considerations:
Glycol is preferred for its non-toxic and non-corrosive nature, ensuring the safety of the
reactor system and the integrity of the chemical process. Additionally, glycol offers freeze
protection, preventing the cooling system from freezing in colder environments.
The reactor is equipped with a capacity of 4 tons and operates within a temperature
range of 10 to 15 degrees Celsius. To maintain optimal reaction conditions, a jacketed design is
employed, with glycol circulating as the working fluid to control the reactor's temperature.
Mesh:
In the enzymatic reactor RV-04, an intricate mesh with a density of 100 holes per
square inch serves as a crucial barrier, effectively preventing enzymes from contaminating the
final product. This finely calibrated mesh acts as a selective filter, allowing only the desired
components to pass through while retaining the enzymes within the reactor system.
Once charged, the enzyme exhibits remarkable longevity, maintaining its catalytic
activity over an impressive span of 250 to 300 batches. This extended lifespan underscores the
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efficiency and reliability of the enzymatic process, contributing to the overall sustainability and
cost-effectiveness of penicillin production.
RV-03 is a crucial unit in the process, where the reaction mixture undergoes a
transformation to achieve a crystal-clear solution. Here's an explanation of RV-03 and the
addition of HCl to clarify the solution:
RV-03:
RV-03 is a designated vessel or reactor within the process flow, designed to facilitate
specific reactions or treatments required to refine the reaction mixture. It serves as a controlled
environment where the reaction conditions can be adjusted to achieve desired outcomes. Rpm in
the reactor is about 90 to 100.Pressure gradient is used for the movement of the fluid in reactor.
Addition of HCl:
The addition of hydrochloric acid (HCl) serves a specific purpose in RV-03. One of the
primary functions of HCl in this context is to adjust the pH of the reaction mixture to a level
where certain compounds or impurities are solubilized or rendered insoluble, leading to the
formation of a clear solution. The vessel for HCl is shown below:
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Clarification of Solution:
The addition of HCl helps in clarifying the solution by neutralizing alkaline impurities or
by precipitating out undesirable components that contribute to the milky white appearance of the
solution. HCl can react with alkaline species present in the reaction mixture, forming water-
soluble salts or complexes that can be easily separated from the solution, resulting in a clearer
and more transparent solution.
Filtration:
After the RV-03 stage, a crucial step involves passing the product through a filter with a
mesh size ranging from 0.1 to 0.5, aimed at meticulously removing any residual enzymes or
contaminants. This filtration process ensures that the product entering the crystallizer is of high
purity, free from any impurities that could potentially compromise the quality of the final
product.
Crystallizers:
In the process, there are two crystallizers involved, which are essential for the
precipitation and crystallization of the desired product from the reaction mixture. Crystallization
is a separation process that involves the formation of solid crystals from a homogeneous solution
or melt. The crystallizers provide controlled conditions such as temperature, pressure, and
agitation to facilitate the nucleation and growth of crystals.
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In the crystalizer unit, glycol serves as a vital cooling agent, maintaining precise
temperature control essential for the crystallization process. The circulation of glycol within the
jacket surrounding the crystalizer vessel ensures a stable and conducive environment for crystal
formation. By regulating the temperature effectively, glycol facilitates the controlled
precipitation of desired compounds, optimizing the purity and yield of the final product. This
meticulous temperature management, enabled by glycol, enhances the efficiency and reliability
of the crystallization process, ensuring consistent product quality.
PH Adjustment:
Ammonium hydroxide is added to the reaction mixture to increase its pH, thereby
shifting the equilibrium towards the formation of the desired product crystals. Controlling the pH
is essential for promoting the precipitation of the desired compound and minimizing the
formation of impurities or unwanted by-products.
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Crystal Formation:
The pH adjustment facilitated by ammonium hydroxide promotes the formation of
crystals by providing favorable conditions for nucleation and crystal growth. By adjusting the pH
to the optimal range for crystal formation, the efficiency and yield of the crystallization process
can be enhanced.
Impurity Removal:
In addition to promoting crystal formation, the pH adjustment with ammonium
hydroxide can also help in the removal of impurities or unwanted species from the reaction
mixture. By adjusting the pH to a level where impurities are less soluble or precipitate out, the
purity of the final crystalline product can be improved.
“Unit Operations”
Centrifugation:
In the process involving the four centrifuges connected to a header vessel containing
IPA (Isopropyl Alcohol), IPA serves multiple important functions. In the centrifugation stage,
four centrifuges are employed, each designed with specific capacities. The first three centrifuges
have a capacity of 80 kg, while the fourth, larger centrifuge can accommodate up to 120 kg of
material. This setup allows for efficient separation and processing of the product on a larger
scale, optimizing the overall production process.
Here's an explanation:
Recycling:
IPA is known for its ability to be recycled and reused in industrial processes. After being
used for washing and purification, IPA can be recovered from the process stream, purified if
necessary, and recycled back into the system for further use. This recycling helps reduce waste,
minimize costs associated with solvent procurement, and promote sustainability in the
manufacturing process.
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Recovery of IPA:
In the process, Isopropyl Alcohol (IPA) is carefully recovered and recycled. The fluid collected
from the centrifuges is directed into a storage pit or tank, where it undergoes heating. Subsequently, in a
distillation column, the components are separated based on their differing boiling points. A condenser is
employed to convert the vaporized IPA back into its liquid form, facilitating its reuse in the production
process. This recycling approach ensures efficient utilization of resources and minimizes waste,
contributing to the sustainability of the overall operation.
Solvent Compatibility:
IPA is compatible with a wide range of materials commonly used in industrial
equipment, including centrifuges. It can effectively dissolve a variety of substances and is
suitable for use in processes involving solid-liquid separations, such as centrifugation.
Smasher:
In the smasher unit, the bulky product undergoes a transformation into a powdered
form, enhancing its surface area. This process is crucial for subsequent operations, particularly in
the fluidized bed apparatus, where increased surface area facilitates better moisture removal. By
breaking down the material into finer particles, the heat transfer process becomes more efficient,
leading to improved drying performance and overall product quality.
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Micronization:
In the jet mill process, micronization is achieved by introducing the material into a
high-speed stream of gas, typically air or nitrogen. Inside the jet mill, the material undergoes
intense collisions and shearing forces, resulting in particle size reduction to the desired range. To
ensure consistent particle size distribution, a classifier is integrated into the system. The classifier
separates particles based on their size, allowing for precise control over the final product's
particle size distribution.
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Compactors:
The compactors, these machines are used to compress the material into compacted
chips or pellets. The material is fed into the compactor, where it undergoes high-pressure
compaction. This pressure, typically exceeding 50 Bar, forces the material particles to adhere to
each other, forming densified chips. The compactors ensure uniformity and integrity of the final
product, enhancing its handling and storage properties. Two compactor are used one having
greater capacity than the otherone.
Cone Blender:
In the process of blending powdered products using a cone blender, homogenization of
the product's moisture content is achieved through gentle mixing and blending. The cone
blender, also known as a conical screw mixer or a tumble blender, consists of a cone-shaped
vessel with a centrally mounted rotating screw or agitator. During operation, the powdered
product is loaded into the cone blender, and the agitator rotates, causing the product to tumble
and mix thoroughly. The conical shape of the vessel promotes gentle and efficient blending by
ensuring uniform movement of the product particles.
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The blending action of the cone blender facilitates the distribution of moisture throughout
the powdered product, resulting in homogenization of the moisture content. This ensures that
each particle of the product comes into contact with moisture evenly, leading to consistent
moisture distribution across the entire batch. The gentle mixing action of the cone blender helps
prevent segregation or uneven distribution of moisture, ensuring that the final product has
uniform moisture content throughout. This is crucial for products where moisture uniformity is
essential for quality and consistency, such as pharmaceuticals, food ingredients, and powdered
chemicals.
Metal Detector:
After blending, the product undergoes quality control measures to ensure its integrity
and safety. A metal detector, capable of detecting particles as small as 0.25 mm, is employed to
screen the product for any metallic contaminants. This step is crucial in maintaining product
quality and safety standards, particularly in industries such as food processing and
pharmaceuticals, where even tiny metal fragments can pose a serious risk to consumer health.
The sensitive metal detector efficiently scans the product, identifying and removing any metallic
impurities present, thus guaranteeing that the final product meets stringent quality control criteria
and is free from potential hazards.
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The metal detector utilized in this process is renowned for its exceptional sensitivity
and precision, making it one of the most advanced detection systems currently available in the
pharmaceutical, as well as the food and beverage industries. Recognized for its unparalleled
performance, this cutting-edge technology sets the standard for metal detection, ensuring
unmatched levels of product safety and quality assurance. Its superior capabilities enable it to
detect even the minutest metallic contaminants, thereby safeguarding consumer well-being and
upholding industry regulations with utmost efficacy.
Finishing processes may include packaging, labeling, and final inspection to ensure
compliance with regulatory requirements and customer specifications. Once finalized, the
product is prepared for transport, utilizing appropriate logistics methods to deliver it efficiently
and securely to its destination. Throughout these stages, meticulous attention is paid to every
detail to uphold product quality and meet customer expectations.
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Uses of Pencillin:
Penicillin, a group of antibiotics derived from Penicillium fungi, is primarily used for
treating bacterial infections. It is effective against a wide range of bacteria, including
streptococci, meningococci, and staphylococci. Some common uses of penicillin include:
Respiratory Infections:
Penicillin may be prescribed for respiratory tract infections, such as pneumonia and
bronchitis, caused by susceptible bacteria. It helps to reduce the severity of symptoms and
shorten the duration of the illness.
Dental Infections:
Penicillin antibiotics are sometimes used to treat dental infections, including dental
abscesses and periodontal infections. They help to control bacterial growth and reduce
inflammation in the affected area.
Preventive Measures:
In certain situations, penicillin may be used prophylactically to prevent bacterial
infections, particularly in individuals at risk of developing complications from certain bacterial
exposures, such as those with heart valve abnormalities before dental procedures.
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Strengthen quality control measures to ensure product quality and compliance with
regulatory standards. Implement robust quality assurance protocols, including regular testing and
monitoring, to detect and address any deviations or issues promptly.
Energy Efficiency:
Develop and implement waste reduction and recycling programs to minimize waste
generation and promote sustainability. Explore opportunities to recycle or reuse process by-
products and wastewater streams wherever possible.
THANK YOU