Compressed air in the pharmaceutical and medical technology sectors
Maximum quality. Minimum risk. Up to Class 0 for uncompromising safety.
In the pharmaceutical industry and medical technology sector, compressed air is a critical factor across the entire value chain – from research and development and the sterile manufacture of active ingredients to cleanroom packaging. As an ultra-pure medium, it powers complex filling lines and tablet presses and serves directly as process air: aerating bioreactors, cleaning glass ampoules and pneumatically conveying delicate powders. A stable compressed air supply also forms the key foundation for on-site nitrogen generation for inerting, proactively preventing oxidation and contamination.
The demands placed on compressors and treatment components in this sector are exacting. Any deviation in compressed air purity can compromise sterility, lead to batch losses or result in regulatory breaches. KAESER’s oil-free compressed air systems are certified to ISO 8573-1 Class 0, guaranteeing that no contaminants are introduced into the air during the compression process. Combined with appropriate treatment, KAESER ensures air purity, dryness and sterility at all times, meeting the stringent requirements of Good Manufacturing Practice (GMP) and international pharmacopoeias.
Compressed air supply in the pharmaceutical and medical technology sectors can be energy-intensive, often accounting for between 10% and 30% of total on-site energy costs. With net-zero ambitions and mounting pressure to meet ESG targets, compressed air station optimisation has become a practical route to cutting energy costs and improving carbon performance. The heat generated during compression can also be repurposed efficiently through heat recovery.
KAESER compressors set the standard through innovative technology and qualifiable processes. Our systems are designed for straightforward validation, offer seamless digital monitoring and use components suitable for medical technology applications. In this way, KAESER supports holistic quality management. We offer tailored, ultra-pure and cost-effective solutions - up to ISO 8573-1 Class 0 - for every sensitive stage of pharmaceutical production.
Applications
Compressed air applications in the pharmaceutical and medical technology sectors
KAESER offers dependable, compliant compressed air solutions across the full spectrum of life sciences: from precise control air for laboratory automation and process air for tablet coating to sterile, oil-free compressed air for cleanroom environments. We deliver the technology to match your specific purity class requirements.
Our services and solutions
Prevention of cross-contamination is paramount in the pharmaceutical and medical technology sectors. KAESER offers individually engineered compressed air systems precisely matched to the sector's stringent regulatory, safety and performance requirements. Our systems deliver consistently reliable, dry and - where required - completely oil-free Class 0 compressed air.
Thanks to their robust design, intelligent control options, and highly efficient treatment components, KAESER compressed air systems ensure stable, verifiable operation, even under the most demanding cleanroom conditions.
Your advantage: KAESER compressed air stations deliver maximum process reliability, minimise the risk of batch losses and secure consistently high purity. This creates the ideal foundation for compliant, efficient and sustainable production.
Regulatory compliance
In pharmaceutical manufacturing, compressed air quality is a decisive factor for patient safety and for securing regulatory approval. KAESER offers systems engineered for full compliance with international standards, such as ISO 8573-1 and ISO 22000.
For pharmaceutical and medical technology companies, GMP requirements and qualification steps are a crucial part of installing new equipment. KAESER provides the relevant documentation and certification to support qualification and acceptance. Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) are additional services KAESER offers to guide customers through the qualification process.
Assured process reliability
Compressed air that comes into direct contact with active ingredients or primary packaging must be free from oil, moisture, particles and microorganisms. Our oil-free rotary screw compressors deliver air in purity Class 0 - the highest level for absolute cleanliness - reliably protecting your products from microbial and chemical contamination.
However, availability is every bit as essential as purity. A failure in the sterile chain can incur enormous costs. With redundant design, predictive maintenance, and intelligent networking, KAESER compressed air systems guarantee a reliable, 24/7 supply.
Efficiency, maintenance and heat recovery
Energy accounts for almost 80% of a compressed air system's total costs and can represent up to 30% of a site's overall electricity consumption. Efficiency is therefore not simply a 'green' objective - it is a decisive competitive advantage. KAESER systems transform waste into added value.
Heat recovery: Up to 96% of the energy used can be recovered as heat - to warm water for cleaning processes, for example, or to support HVAC systems in production facilities. This improves your carbon footprint and can dramatically reduce operating costs.
Carefully designed maintenance concepts and straightforward access to every component enable short service intervals without lengthy downtime. This guarantees a consistently high-performing, hygienically flawless, and cost-effective compressed air supply, maintaining safe production in the service of health.
Interesting facts
FAQs, facts and useful insights about the pharmaceutical and medical technology sectors
The central technical reference is ISO 8573-1, which defines the limit values for particles, residual oil content and moisture. For highly sensitive processes where air comes into contact with medicines, implants or surgical instruments, Class 0 is the gold standard: it guarantees that the compressed air is completely oil-free and technically pure.
Our solutions also align with:
- GMP guidelines (Good Manufacturing Practice): ensuring seamless quality control.
- Pharmacopoeias: specifications for gas purity in production.
- ISO 13485: quality management systems for medical products.
Wherever compressed air comes into direct contact with a product or its packaging, and where contamination could endanger patient health, oil-free compressed air in accordance with ISO 8573-1 is mandatory. Class 0 compressors eliminate the risk of hydrocarbons in the air stream, giving you maximum assurance for your audits.
Typical applications:
- Sterile aeration: fermentation processes in bioreactors or cell cultures.
- Product coating: spray application of protective coatings to tablets or coated pills.
- Pneumatic conveying: transport of active ingredient powders and granulates without loss of quality.
- Primary packaging: cleaning, filling and sealing of ampoules, vials and blister packaging under cleanroom conditions.
- Medical technology: cleaning and drying of surgical instruments and catheters after sterilisation.
For these applications, KAESER supplies not only the compressor but a complete system, including high-precision filtration and desiccant drying, to maintain consistent dew point stability even under extreme conditions.
In an environment where data integrity determines success, KAESER MEASURING TECHNOLOGY delivers the transparency your quality assurance demands. High-precision sensors monitor pressure dew point, residual oil content and particle concentration in real time, forming the foundation of a secure holistic system.
Continuous monitoring provides a proactive early-warning system that detects the smallest deviations before any batch is put at risk. Seamless, legally compliant logging of all parameters also ensures smooth documentation for regulatory audits, such as those based on FDA requirements. Furthermore, system monitoring actively supports process optimisation: Monitoring of sterilisation cycles and cleanroom pressure reliably prevents microbial ingress, ensuring stable, verifiable operation at the highest level.
In pharmaceutical production, climate control and process heat are often significant cost drivers. KAESER compressed air systems offer enormous savings potential: almost all of the electrical energy consumed is converted into heat during compression. Rather than letting this valuable energy dissipate into the surroundings, our heat recovery systems put it to work on-site.
The recovered energy can be used in various ways - to heat process water for cleaning systems (CIP/SIP) efficiently, for example, or to preheat laboratory water. HVAC is another area where the system demonstrates its value: by providing targeted support for heating in production and storage facilities, it significantly reduces your site's carbon footprint.
The result is enhanced plant efficiency and significantly reduced primary energy costs offering complete peace of mind, as heat recovery has no impact on the compressed air's strict hygiene standards.
