Polysulfone Surpasses Polycarbonate in Biotech Sight Gauges, Elevating Sterility and Performance

After rigorous testing, SaniSure – a global leader in single‑use fluidic systems for drug and vaccine manufacturing – selected Solvay Specialty Polymers’ transparent Udel P‑1700 polysulfone (PSU) to produce customized tri‑clamp sight gauges for bioprocessing. The material delivers unmatched strength, optical clarity, heat resistance, hydrolytic stability, and maintains its mechanical properties even after steam sterilization.

Key attributes of the new tri‑clamp sight gauges include high‑temperature stability and excellent chemical resistance, essential for demanding biopharma workflows.

SaniSure’s broad expertise spans thermoplastic and thermoset extrusion, molding, assembly, and fabrication. Their portfolio covers single‑use assemblies, bottles, tubing, fittings, and custom fabrications.

In addition to the transparent Udel P‑1700 PSU tubing, SaniSure incorporated an opaque white grade of Udel PSU for the sight‑gauge‑to‑tubing connection. The white PSU is injection‑overmolded onto the gauge, where a hygienic gasket is secured with a mechanical clamp. Both materials are free of animal‑derived components and comply with USP Class VI and ISO 10993 biocompatibility standards.

Robert DuPont, SaniSure’s Product Development Manager, calls Udel P‑1700 PSU a major breakthrough for the pharmaceutical industry. “The rigorous regulatory testing from Solvay, particularly for extractables and leachables under the BioPhorum Operations Group (BPOG) standard, gave us confidence,” he says. “Based on the exceptional performance of Udel PSU and our productive collaboration with Solvay, we plan to expand its use into new products currently under development.”

Initially, polycarbonate (PC) was considered for the application but fell short due to stress cracking, hazing, and poor compatibility with clean‑in‑place (CIP) chemicals commonly used in biopharma. Extensive trials confirmed that Solvay’s Udel PSU excels, offering 240 °F high‑temperature stability, superior chemical resistance, and a proven track record across biopharma products.

SaniSure’s decades‑long proprietary PSU processing methods and specialized equipment accelerated development, enabling a smooth, transparent wall and maintaining the large outside diameters required for these sight gauges.

Given the critical nature of the application, SaniSure prioritized material excellence over cost. While material cost is a small fraction of the overall product expense, Solvay’s Udel PSU supports a highly efficient manufacturing process with minimal rejects, reinforcing quality and reliability.