Industrial Preparative HPLC (DAC) System
Industrial Preparative HPLC (DAC) System
Mechotech designs and manufactures industrial preparative HPLC systems built around dynamic axial compression (DAC) columns for production-scale purification of peptides, active pharmaceutical ingredients (APIs) and fine chemicals. In a DAC column a piston keeps the packed stationary-phase bed under axial compression, so the bed stays uniform in a large-diameter column. The system is a process skid: DAC column, multi-solvent inlet, high-pressure pumps, detection, automatic fraction collection, slurry tank for packing and auxiliaries. Column size, flow, hazardous-area construction (Mechotech’s site navigation lists this system as the Industrial EX-Proof Prep-HPLC) and control scope are configured to the customer’s separation and facility. It follows peptide synthesis in Mechotech’s peptide and purification line; the laboratory and semi-preparative system is the separate Preparative & Semi-Preparative HPLC page.
A Mechotech industrial preparative HPLC system is centred on a DAC column in which a piston continuously compresses the packed bed, limiting the voids and channelling that would otherwise degrade a large-diameter separation. A multi-solvent inlet and high-pressure process pumps deliver isocratic or gradient mobile phases, and automated valves manage forward-flow separation, back-flush and bypass wash cycles so the column can be packed, run, cleaned and re-equilibrated under recipe control. A detector monitors the eluent and an automatic fraction collection system diverts each cut into its own vessel. Options that are specified per project include EX-proof or standard construction, high-pressure safety valves and interlocks, and the control and documentation scope. Column inner diameter, flow rate and throughput are configured to the upstream synthesis or fermentation stream and the required cycle time, and final parameters are established during process development and pilot validation.
Technical Specifications
| Product | Industrial Preparative HPLC (DAC) System |
|---|---|
| Technology | Industrial preparative HPLC with a dynamic axial compression (DAC) column |
| Working Principle | A piston holds the packed stationary-phase bed under axial compression so the bed stays uniform in a large-diameter column |
| Column | DAC column; inner diameter and bed length configured to the separation, throughput and facility |
| Pumps | High-pressure process pumps with a multi-solvent inlet; flow and pressure configured to the column and method |
| Mobile-phase Delivery | Isocratic or gradient, configured to the method |
| Wash Modes | Forward, back-flush and bypass wash cycles, where specified |
| Detection | UV process detector with a preparative flow cell; wavelength configuration confirmed per project |
| Fraction Collection | Automatic valve-based fraction collection and recycle |
| Column Packing | Slurry tank with slurry packing and piston compression |
| Hazardous-Area Construction | EX-proof or standard construction; rating and certification specified and confirmed per project and facility classification |
| Product-contact Material | Stainless steel; polymer wetted parts selected for the mobile phase and confirmed per project |
| Safety | High-pressure safety valves, pressure interlocks and alarms, where specified |
| Control | Automated valve and pump sequence under control software; audit-trail / electronic-record scope confirmed with the client |
| Plant Capacity | Configured to requirement |
| Compliance | GMP hygienic design; full documentation for qualification |
| Output | Purified fractions collected by the fraction collector, for downstream concentration, solvent recovery and drying |
Plant Capacities
| Plant Scale | Column Size / Throughput | Typical Use |
|---|---|---|
| Pilot | Configured to your separation and trial plan | Method scale-up, parameter validation |
| Semi-Commercial | Configured between pilot and commercial scale | Scale-up trials, contract manufacturing |
| Commercial | Configured to confirmed batch size and product volume | Production-scale purification |
Column inner diameter is the main scale-up lever; the pumps, wash valves, fraction collection and slurry tank are scaled to the confirmed column. Flow rate and throughput are configured to the upstream synthesis or fermentation stream and the required cycle time, and are established during process development and pilot validation.
Manufacturing Process
Column Packing (Slurry)
Stationary phase is slurried in the slurry tank and pumped into the column, then the piston compresses the bed to a stable, homogeneous packing.
Axial Compression
The piston holds the packed bed under compression during operation, keeping the bed uniform and limiting voids and channelling at working flow.
Feed Injection
The crude peptide, API or intermediate feed is loaded onto the column head, with the load matched to the bed capacity and the target purity set with the client.
Gradient or Isocratic Separation
The high-pressure pumps and multi-solvent inlet deliver the mobile phase so the target compound resolves from impurities along the packed bed.
Detection & Automatic Fraction Collection
The detector tracks each eluting band and automated valves divert the target cut, side fractions and recycle streams into their respective vessels.
Wash Cycles
Where specified, forward, back-flush and bypass wash modes strip strongly retained material and clean the flow path between runs.
Re-Equilibration & Cycling
The column is re-equilibrated to starting conditions and the cycle repeats under recipe control for the next injection.
Downstream Workup
Collected fractions pass to concentration, solvent recovery and drying, for example the rotary evaporator, acetonitrile recovery system and freeze dryer in Mechotech’s peptide line.
Major Plant Equipment
- Dynamic axial compression (DAC) column
- Slurry tank for column packing
- High-pressure process pumps with multi-solvent inlet
- UV process detector with preparative flow cell
- Automated valve manifold (forward, back-flush and bypass wash, where specified)
- Automatic fraction collection and recycle system
- High-pressure safety valves and interlocks, where specified
- Solvent, buffer and fraction vessels
- Control system
Plant Output
Applications
- Peptide purification and polishing at production scale
- Active pharmaceutical ingredient (API) purification
- Fine-chemical and intermediate purification
- High-value natural-product isolate purification
- Purification stage of a peptide synthesis-to-final-product line
Key Features
Dynamic Axial Compression Column
A piston keeps the packed bed compressed during operation, so the bed stays uniform in a large-diameter column.
Multi-Solvent Inlet
A multi-solvent manifold with high-pressure pumps supports isocratic or gradient mobile phases.
Automated Valves & Fraction Collection
Packing, injection, fraction collection, wash and re-equilibration are sequenced under recipe control.
EX-Proof or Standard Construction
Hazardous-area (EX-proof) or standard construction is specified per project and facility classification.
Safety Devices
High-pressure safety valves, pressure interlocks and alarms are fitted where specified.
Complete Process Skid
Supplied with slurry tank, pumps, detection, fraction collection and auxiliaries as one configured skid.
Frequently Asked Questions
What is an industrial preparative HPLC (DAC) system?
What is a dynamic axial compression (DAC) column?
What column sizes and throughput are available?
Can it be built for a hazardous area?
What are forward, back-flush and bypass wash modes?
What compliance and documentation support is available?
How does this system differ from the Preparative & Semi-Preparative HPLC system?
Where does it sit in the peptide line?
Does Mechotech supply it as a turnkey skid?
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