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How will the EU decision to ban mercury lamps affect process photometers and the industries that have relied on them for many years? In a significant move towards sustainability and public health, the European Union has decided to ban mercury lamps by 2025. This decision is driven by the need to reduce environmental pollution and protect public health from the toxic effects of mercury.
Pharmaceutical companies worldwide have become reliant on mercury lamp based photometry for applications a varied as
So where does that leave laboratories and facilities that heavily rely on the use of filament lamps, commonly made with mercury, for their production, processes and equipment? LED lamps are the answer. They are widely available and far more eco-friendly. But what are the differences? Here is your guide to Mercury Filament Lamps and LEDs to help you prepare for the regulation change. 1. Efficiency Traditional mercury lamps are generally less energy-efficient. They require a significant amount of power to operate and can produce a lot of heat. They also have a warm-up period before they reach full brightness, which can delay the start of analysis. They can also degrade over time, affecting the consistency and accuracy of measurements. LED lamps are much more energy-efficient, consuming less power for the same amount of light output. They reach full brightness instantly and can remain at a consistent level of brightness leading to more accurate readings. 2. Longevity The lifespan of mercury lamps is relatively short. They typically need to be replaced more frequently, leading to higher maintenance costs and downtime for the equipment, like analysers, that they may reside in. LEDs have a much longer lifespan, often lasting tens of thousands of hours. Fewer replacements mean less intervention and keeping your laboratories within budget. 3. Safety and Environmental Impact Mercury lamps contain mercury, a toxic metal substance that poses environmental and health risks if not handled and disposed of properly. Breakage can release mercury vapour, which is also hazardous. LEDs do not contain mercury or other harmful substances, making them safer for both users and the environment. They are easier to dispose of in the rarer instances where you have to replace them. 4. Quality This is the all-important factor. The light spectrum from mercury lamps can be limited and may not be ideal for all types of analysis. They often produce ultraviolet light, which can be useful but also limiting depending on the application. LEDs can be designed to emit specific wavelengths and have a more controlled and customisable light spectrum, making them suitable for a broader range of analytical applications. We understand that many of you will still be using mercury lamps, particularly in the pharmaceutical industry, and changing them can be difficult due to validation costs and constraints. However, with the legislation change on the horizon, we can help you with the transition. Our partners, Kemtrak, have never used mercury in their products and can help your operations go green. Their range of high-performance industrial process photometric, fluorescence and turbidity instruments can be used in a wide variety of applications. Besides the upcoming ban there are good reasons to change from mercury lamp based photometers to LED’s as they offer a multitude of benefits.
The engineering team at here Fullbrook Systems can discuss your specific needs and ease the transition between LED and Mercury lamps. Reach out today.
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 The versatility and efficacy of chromatographic techniques have made them essential in both large scale and analytical separation.
Chromatography is widely used in bioprocessing to separate protein molecules from concentrated process fluids. The centre of a chromatography system is a column, filled with a media specific to the separation being carried out. How is the Kemtrak DCP007 Photometer used for chromatography product detection? Chromatography is used for protein separation and purification in biotechnology and can require one or more chromatography steps during downstream processing. Separation through chromatography requires specialized equipment to ensure maximum yield and purity. A Kemtrak DCP007-UV photometer is optimally designed for in-line real time measurement and control, allowing the detection of a protein rich solution to be diverted for collection. With an optional NIST Validation accessory mounted it will allow the user to do a validation of instrument in-line in a simple way. How does the Kemtrak DCP007 Photometer help with measuring protein levels? Advances in bioprocessing methods have led to protein products being expressed and concentrated to higher and higher levels. Higher protein concentrations mean higher absorbance and therefore, UV analysers need the ability to measure accurately at these higher absorbance levels. While absorbance measurement is essentially linear, many traditional instruments use light sources that generate a broad spectrum of wavelengths that cause stray light to enter the measurement cell resulting in a non-linear response to protein concentration, particularly at high levels. Also, traditional light sources are sensitive to temperature, generating a lot of thermal energy, and constantly drift due to deterioration. This makes them unsuitable, particularly for fragile protein molecule work. How do I install the Kemtrak DCP007 for post-column chromatography monitoring? The Kemtrak DCP007-UV analyser will deliver accurate, reliable, and repeatable post column UV and are a minimum requirement during chromatographic separation to ensure good protein fraction purity and maximum yields. With the unique Kemtrak zero dead volume measurement cell installed at the column outlet, the Kemtrak DCP007-UV analyser can provide single or dual wavelength UV absorbance analysis, in real time, for improved control of the separation process. With this, the need for offline testing and manual analyses is greatly reduced. Furthermore, the use of solid-state light sources provides the ability to measure up to 4.5 Au at 280 nm and to monitor high concentration processes up to 90 OD linearly without “peak clipping” and the undesirable effects of “hot” and powerful UV light sources on the product. Therefore, the Kemtrak DCP007-UV is the best analyser for chromatographic separation. For more information about how the Kemtrak DCP007 can assist with your chromatography, please contact us at: [email protected] or call: 01442 876777. Recently, we looked at how the Kemtrak DCP007-NIR can be used to improve chromatographic separations. In this week’s post, we analyse how this popular and diverse instrument can also be used to improve solvent concentration control.
The versatility and efficacy of chromatographic techniques have made them essential in both large scale, and analytical separations. Chromatography is widely used in bio-processing to separate protein molecules from concentrated process fluids. The centre of a chromatography system is the column, filled with a media specific to the separation to be carried out. How is the technique applied? Solvent gradient control can significantly enhance peak separation and the process economy of chromatography applications. An in-line quantitative sensor permits on-line mobile phase assessment, which with controlled feedback can guarantee accurate and reproducible results. Controlled gradients minimize the effects of changing properties of the stock solvents. How was the instrument installed? Pre-Column chromatography monitoring: The Kemtrak DCP007-NIR mounted in-line before the chromatography column, continuously monitoring the solvent concentration, gives the user control over the composition delivered to the chromatography column. The online monitoring of solvent composition is more significant than measuring physical parameters like mass flow alone. As It allows the generation of batch reports that confirm the actual gradient composition and inhibits the incorrect use of a solvent. The Kemtrak hygienic measurement cells available with FDA and UPC VI approved materials, convenient zero dead volume design; contain no electronics or moving parts for ease of use. There are two versions of the Kemtrak DCP007-NIR currently available: DCP007-NIRL (850 – 1550 nm) for measurement of 0 - 100% water and solvent gradients. DCP007-NIRH (850 – 2000 nm) for trace water and hydrocarbon detection. This model incorporates a multiple stage Peltier cooled and temperature regulated photodiodes and NIR LED light source for the very best in stability and performance. For more information about this instrument and how it can help you with your chromatographic processes, please call us on: 01442 87677 or email: [email protected], where we will also be happy to provide you with a free, no obligation quote. In this week’s blog post, we discuss how Kemtrak’s popular photometer can be used to improve the efficiency of chromatographic separation processes. What are chromatographic techniques? Chromatography is widely used in bioprocessing to separate protein molecules from concentrated process fluids. The centre of a chromatography system is a column, filled with a media specific to the separation being carried out. The versatility and efficacy of chromatographic techniques have made them a crucial part of both large scale and analytical separations. The current methods of chromatographic separation are as follows: Gel filtration – refers to sorting the material by molecular size. The physical dimensions of the molecule determine the separation because proteins are naturally spherical. This means the molecular weight of the protein will be proportional to its size, allowing for separation based on this property. Larger molecules pass more slowly through the column media, while smaller molecules pass through more quickly. Ion exchange – refers to sorting the material by electrical charge. Separation works by opposite charge attraction and like charge repulsion. Using a specific charge within the column media allows for attraction and binding of the molecule(s) of interest. Hydrophobic interaction – refers to sorting the material by degree of Hydrophobicity. Separation relies on polar (hydrophilic) molecules “sticking” together and repelling those which are non-polar (hydrophobic). Affinity - this method uses a bio-specific binding site. This is a section of a molecule in which the shape and distribution of charged and hydrophobic groups allow for highly specific binding to a corresponding site on another molecule. The fit between the two sites is analogous to a lock and key. How does chromatography work? Chromatography is a process for separating components of a mixture. To start the process, the mixture is dissolved in a substance called the mobile phase. This then carries it through a second substance called the stationary phase. The different components of the mixture travel through the stationary phase at different speeds, causing them to separate from one another. The nature of the specific mobile and stationary phases determines which substances travel more quickly or slowly, and this is how they are separated. These different travel times are known as retention times. A chromatography gel is designed to have one half of this lock and key (the ligand), making it stationary within the column. As the product solution is passed through column, the specific mating molecules are bound in place until they are eluted from the column. Examples of affinity interactions include the binding between antibodies and antigens, and enzymes and substrates. The molecular properties utilised in chromatographic separation can be seen in the figure below:  Separation through chromatography requires highly specialized equipment to ensure maximum yield and purity. A system may include a variety of instruments and sensors for pre - and post - column control.
Nearly all proteins absorb UV light at 280 nm, the primary reason for this is due to the aromatic amino acids, e.g. phenylalanine, tryptophan, tyrosine, and histidine. How does installing a Kemtrak DCP007 help improve chromatographic processes? Installing a Kemtrak DCP007-UV photometer, measurement cell at the column outlet, allows the presence of proteins to be detected, and therefore collection/pooling to begin. It is vital that any UV analyser has no dead or hold up volume to ensure crisp, sharp peaks are detected. UV analysers utilizing measurement cells with internal hold up volumes can lower the purity of the collected protein because of dilution. Dilution blurs sharp peak detection lines, and can cause lower yields. Using a Kemtrak DCP007-NIR photometer, mounted pre-column to determine solvent concentration/composition, allows for a feedback control of the solvent “mobile media” feed through the column, and increases the accuracy and repeatability of the chromatography system. With the unique zero dead volume Kemtrak measurement cell installed, the Kemtrak DCP007 analyser can provide single or dual wavelength absorbance analysis, in real time, for improved control of the chromatographic separation processes. Therefore, the Kemtrak DCP007 is the recommended analyser for chromatographic separations. To find out more about the Kemtrak DCP007 (UV or NIR) Photometer, please visit our website: or call: 01442 87677 to discuss your requirements further. We will also be happy to provide a free, no obligation quote. The methods, applications, and benefits of the Kemtrak DCP007 include the following:
• ICUMSA Methods GS 1/3-7, GS 2/3-10 and GS 2/3-10 • Determination of the solution colour of white, brown, and raw sugars as well as coloured syrups • Decolourisation of glucose syrups • A charcoal filter alarm • Manufacturing quality and control • Real time in-line continuous measurement • A zero maintenance LED light source that never needs replacing. What is the ICUMSA Colour Scale and how is it used in sugar production? The International Commission for Uniform Methods of Sugar Analysis (ICUMSA) describes a range of methods for the colorimetric determination of filtered sugar suspensions at known concentrations (Brix values). The ICUMSA colour scale is used to measure the grade and quality of the sugar. The colour of sugar directly relates to the degree of refining – raw sugars being dark brown in colour whilst highly refined sugars are white in colour. The ICUMSA colour scale is a measurement of the yellowness of the sugar resulting from residual molasses not removed in the refining process and can be used to monitor and control the manufacturing process. How can the Kemtrak DCP007 be applied to this process? The Kemtrak DCP007 process photometer has a high-performance long-life LED light source, precision optical filters and robust fibre optics that results in an ICUMSA colour analyser with outstanding performance and reliability. The Kemtrak DCP007 process photometer is recommended to accurately measure ICUMSA colour. The Kemtrak DCP007 employs proprietary dichromatic measurement technology that compensates for particulates, allowing accurate colour measurement without the need for filtration. Due to the proprietary dichromatic four channel measurement technology, particulates in the process media can be compensated for in real time providing an accurate measure of colour without the need for filtration. A primary “absorbing” wavelength then accurately measures colour changes in the process medium, while a second reference wavelength, which is not absorbed by the process medium, compensates for particulates and/or fouling of the optical windows. Since optic fibres are used to transfer light to the measurement point and back, the measurement cell contains no electronics, moving parts or sources of heat that result in condensation on the optical surfaces. Standard measurement cells are machined in sanitary grade stainless steel with sapphire windows. How should I set up and configure the Kemtrak DCP007 for my own work? ICUMSA recommend the absorption of light at 420nm for white and light-coloured sugars and 560nm for darker sugars. 720nm is recommended for the reference wavelength to measure and compensate for the turbidity of the solution. The Kemtrak DCP007 process photometer will accurately measure ICUMSA colour for a known concentration sample using the Brix value (degrees Brix or °Bx). ICUMSA colour is calculated as follows: ICUMSA Colour = 1000 × As/b c Where: As = absorbency of the solution (DCP007 primary measurement) b = the optical path-length (cm) c = concentration (g/mL) (using the Brix value). Colour score is expressed in RBU (reference base units) per ICUMSA standard method(s). Where an end user specific base reference is used, the DCP007 can be adjusted accordingly. The process Brix value, measured using a separate density or refractive index analyser, is input into the Kemtrak analyser through a 4-20mA analogue input to correct for differences in sugar concentration. As an alternative where a live density measurement is not available, process Brix values can be manually entered into the analyser. The Kemtrak DCP007 should be configured for the desired measurement range for maximum resolution and accuracy. An optical path-length of at least 10 cm or more is recommended for low colour white sugars, whilst shorter path-lengths are necessary for darker sugars. Please contact us directly for specific configuration details regarding measurement wavelength and selection of optical path-length for the desired measurement range. Where can I find out more about the Kemtrak DCP007? Head over to our dedicated webpage on the Kemtrak DCP007 for more information on this popular instrument. To discuss your requirements or for a free, no-obligation quote, please call us on: 01442 876777 or email: [email protected]. What is crude oil? Crude oil is a yellow-to-black liquid consisting of hydrocarbons of various molecular weights and other liquid organic compounds. Crude oil will not mix with water, however under certain conditions crude oil will form an oil-in-water emulsion with a turbidity proportional to the oil concentration. The Kemtrak TC007 can be used to measure:
How can the Kemtrak TC007 be used to measure crude oil in water? Crude oil in water can be accurately measured using a Kemtrak TC007 process turbidimeter. One of the main benefits of the Kemtrak TC007 process turbidimeter is that all of the electronics, including the long-life, high performance LED light source and photodetectors, are encased within the TC007 analyser enclosure, allowing safe operation in even the most hazardous of environments. Industrial grade optic fibres are used to transfer low power cold light from within the TC007 analyser enclosure to the sampling point and back. As crude oil will not mix with water, it is vital that the sample under analysis has a turbulent flow to ensure sample homogeneity. The image below shows 5% light crude oil in water directly after being shaken (left) and then after five minutes (right):  What were the results of the analysis? The calibration below was made using light crude oil (ρ=830 kg.m -3 @15°C, ν=3.51 mm.s -1 @20 °C) between 0 – 5 % oil in distilled water. The sample was hand shaken (5s) then immediately analysed.  How do you install the equipment to undertake this analysis of crude oil in water? The most critical factor necessary for this analysis is a turbulent flow. It is recommended to use a narrow bore measurement cell and install this on a bypass line where water is available to zero the instrument and flush the cell when not in use. A narrow bore 1⁄4” or 1⁄2” NPT thread type measurement cell is typical for this application. Under operation the high-speed turbulent flow will keep the sapphire windows free from deposits. When not in use the measurement cell should be flushed with water to prevent sticky deposits from accumulating on the optical surfaces. The image below shows the Kemtrak 1⁄4” NPT industrial fibre optic measurement cell available in 316L, Monel 400, titanium or Hastelloy.  The cell has the added benefits of being maintenance free and containing scratch-resistant sapphire windows. In addition, as there are no electronics or moving parts, this makes it the perfect choice for use in hazardous areas.
Where can I find out more about the Kemtrak TC007 and its applications? To discover more about how this popular instrument can help with colour monitoring, chemical concentration, water measurement in organics, and more, please contact us on 01442 876777 or email us at: [email protected]. Inline process refractometers and sensors can perform industrial measurements continuously, and in real time. This technology is also known as PAT (Process Analytical Technology), and here at Fullbrook Systems, we provide Schmidt & Haensch’s leading range of inline refractometers that allow you to monitor and control your processes without product loss or process divergence. With Schmidt & Haensch’s process refractometers, quality control and the determination of liquid concentration and mixing ratios becomes simple. Measurements are always reliable and independent of turbidity, colour, absorption, and viscosity. This ensures the highest precision and improved process control. How does Process Analytical Technology work? Process Analytical Technology (PAT) is a manufacturing methodology for high value chemicals and pharmaceuticals. Critical Process Parameters (CPPs) and Key Performance Indicators (KPIs) of the process are comprehended, well-defined and continually monitored to ensure that the pre-defined Critical Quality Attributes (CQA) of the final product are consistently achieved. PAT measures key quality and performance indicators in both raw and in-process materials in real-time. A well-designed PAT-based process is stable, ensuring that the critical parameters and indicators remain within pre-described limits to safeguard product quality and process safety. What instruments does the range include and what are their benefits? The current range of Schmidt & Haensch inline refractometers include:
 Which industries can these refractometers be applied to?
The refractometers from Schmidt & Haensch can be used in the following industries:
To find out more about how our inline refractometers can help you, please call us on: 01442 876777 or email us at: [email protected] where we will also be happy to provide you with a free, no obligation quote. If your research and production require accurate measurement of light scattering components, both in-line and in real time, then the Kemtrak Inline Turbidity Meter offers an ideal solution. This easy-to-use industrial process fibre optic turbidimeter contains long-life solid state LED lamps and precision fibre optics to provide drift and noise-free measurement at extremely high precision. Hassle free operation is ensured by automatic compensation of sample colour and fouling of the optical windows. The scratch resistant sapphire windows have no electronics or moving parts, making the unit appropriate for use in hazardous areas, as well as making them maintenance free. Other benefits of this popular piece of kit from Kemtrak include: • ISO 7027:1999(E) compliant • Reliable and robust infrared LED lamp • Extensive range of robust fibre optic measurement cells • Analogue output (0/4-20 mA) • Local and web based graphical user interface (TCP/IP). How does the Kemtrak Turbidity Meter work? The turbidity meter is made up of a control unit, flow cell and fibre optics, and is designed to measure the lack of clarity or “cloudiness” of a fluid caused by undissolved particles. Modern turbidimeters use a technique called nephelometry, which measures the amount of light scattered at right angles to an incident light beam. Both transmitted light and scattered light at 90° is measured and mathematically combined using a ratio algorithm to calculate the turbidity of the sample. The dual detection system and ratio algorithm then provides a turbidity measurement that has significantly better performance with coloured and/or light absorbing samples. A long-life LED light source is used to produce reliable turbidity measurements from 0.01 to over 4 000 NTU depending upon the configuration of the optical measurement cell or probe. This means the Kemtrak TC007 is an instrument of high accuracy with long-term calibration stability. What applications is the Kemtrak Turbidity Meter normally used for? The Kemtrak is typically applied in: • Filtration monitoring • Centrifuge control • Interface detection • Phase separation • Leak detection • Oil in water • Quality control To find out more about how this technology can benefit your research, production, or development, get in touch by calling: 01442 876777, or email us at: [email protected].  At Fullbrook Systems, we offer a range of Kreis Basket Mills that are designed for milling low-to-medium viscosity products used in the following industries: • Chemical • Pharmaceutical • Cosmetics • Marine, industrial, and leather paints • Printing inks • Protective coatings • Wood varnishes • Ceramic slurry. Kreis Basket Mills are fast-running, high-performance batch mills with variable speed adjustment using modern frequency converter technology, ideal for the fine dispersing and grinding in the batch production. When used with the Kreis Dissolver, extremely high product qualities and very short grinding times are achieved. For both processes only one production container is required, and after the pre-dispersion with the Kreis Dissolver the grinding process is carried out in the same container with the Kreis Basket Mill. As well as a laboratory pilot version, the Kreis basket mill can also be purchased with either a flat, vacuum or gas cover. The main features include: • A cover system for various container diameters • Batch sizes of 1 to 5000 litres • Fine grinding in batch production (<5 μm) • Height-adjustable grinding basket • Cooled grinding basket • Automatic cooling control Key to short production times, Kreis Basket Mills also allow for continuous temperature measurement with limit value and are optimized for operation with KREISIT® grinding beads. Other options include a double pump disc, a mixing container with a double jacket for cooling, a cleaning container, and a drain tray. To find out more about how Kreis Basket Mills can help you with your research, development, and production by contacting us today at: [email protected] or calling: 01442 876777.  The Kemtrak NBP007 Backscatter Probe is a popular instrument that offers a great solution for:
The Kemtrak NBP007 overcomes the limitations of traditional turbidity based optical measurement instruments, which stop working at approximately 1% suspended solids due to the extremely high optical density. In contrast, the output of a Kemtrak backscatter probe will continue to increase with sample concentration ensuring a reliable measurement. For the first time, the operator can also monitor and retain complete control over their process at any concentration. This means any process changes can be quickly implemented that results in substantial cost savings. Other benefits include:
The robust industrial fibre optic probe with scratch resistant sapphire optics, no electronics and no moving parts is well suited for both ordinary and hazardous area installation and can withstand high temperature process streams or sterilization cycles. A built-in graphical internet-based interface allows for remote operation, calibration, validation, and data trending using a standard web browser. To find out more about how the Kemtrak NBP007 can help you with your production, research, or development, please get in touch at: [email protected] or call: 01442 876777.  |
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