Service
FROM COMMISSIONING TO RELIABLE PRODUCTION
Successful plant operation begins with professional commissioning. Drawing on the experience gained from numerous industrial installations worldwide, our engineers ensure a fast, stable and reliable start-up, enabling your plant to reach its specified performance quickly and safely.
Membrane module installation and training
Correct installation of the membrane modules is essential for reliable plant operation and long-term performance. Our specialists install the modules in the vacuum vessels, verify that the system is ready for commissioning and work closely with your team throughout the installation process.
We also provide practical training on module installation, inspection and replacement procedures, enabling your maintenance personnel to carry out future service work safely and efficiently.
Plant start-up and commissioning
Commissioning is a critical phase in every project, where software, process control and plant operation must work together reliably. Our engineers manage the complete start-up process, drawing on extensive experience from industrial installations to identify and resolve potential issues before they affect production.
We support your operators throughout commissioning, optimise process parameters, provide practical training and monitor plant performance until stable operation has been achieved.
Your role: You prepare the installation site and ensure that all required utilities, such as electricity, cooling water and compressed air, are available. Together, we ensure a smooth, efficient transition from installation to reliable production.
Pilot testing - on site or in our test centre
For an initial “proof of concept”, we rent out pervaporation pilot plants for on-site testing at your premises upon request. While your team provides the required utilities and operates the unit, our engineers support the testing programme and evaluate the results together with you.
Pervaporation: For pervaporation tests, we generally recommend conducting them in our own laboratories. Our experienced R&D team carries out pervaporation tests rapidly and in a cost-efficient manner.
Pressure-driven processes: For pressure-driven tests (nano/ultrafiltration), testing at your site is often the better option, as larger product volumes are readily available and pilot plants can be integrated directly into your process.
Qualification support for the pharmaceutical industry
The qualification of a plant in the pharmaceutical sector is a complex regulatory process. We provide a comprehensive and traceable documentation to support your final product validation.
- Engineering and Documentation: From the earliest design phase, we carry out design reviews and prepare the required engineering documentation. Functional specifications are developed according to the “Equipment Modules” concept, which can be implemented within the GAMP-based automation strategies.
- Certificates and documentation: We deliver our plants with a comprehensive documentation package, including 3.1 material certificates, calibration certificates for instruments and FDA certificates of conformity.
- Qualification Tests: We perform Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) according to approved test protocols. The resulting documentation provides an essential foundation for the qualification and validation of your pharmaceutical production process.
Frequently asked questions
What exactly does DeltaMem’s "Plant Start-up" service include?
Our service covers the complete commissioning process. Our process engineers support commissioning, optimise operating parameters, train your operating personnel and assist with process monitoring and troubleshooting to ensure a smooth transition to reliable production.
How long does it take from delivery to plant start-up?
This depends largely on site conditions. Once the necessary infrastructure is in place and all connections are prepared, plant start-up typically takes place around six months after delivery.
What is the difference between FAT and SAT?
The Factory Acceptance Test (FAT) is carried out at our facility prior to delivery to verify that the plant has been manufactured in accordance with specifications. The Site Acceptance Test (SAT) is carried out after installation at your site, to confirm that the plant operates as specified under actual operating conditions.
Does DeltaMem recommend on-site pilot testing?
Not in all cases. For pervaporation applications, we generally recommend laboratory testing in our dedicated test centre. Thanks to our specialised equipment and extensive experience, tests can usually be carried out more quickly, more efficiently and under well-controlled conditions. For pressure-driven membrane processes, such as nanofiltration and ultrafiltration, on-site pilot testing is often the preferred option, as larger product volumes are available and the pilot unit can be evaluated directly under actual process conditions.