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High functionality in minimal space

Elimination of dead space volume supports faster cleaning and of course means better process efficiency
High functionality in minimal space

High functionality in minimal space: multiport valves like the Robolux ensure compact processes, facilitate excellent cleaning and increase process reliability, therefore contributing to improved product yield. Based on diaphragm valve technology, this generation of patented valves combines independent dual- process switching functions – or two seats in a single body – with a single diaphragm and single actuator.

Hygienic processing places high demands on the reliability and cleanability of production facilities. These requirements are especially high in separation processes like filtration and chromatography, and are significant in ensuring purity of media by maintaining sterile process conditions. The mixing of different media in the manufacture of nutrient solutions processes like fermentation demands absolute sterility. Common challenges such as corrosion in pipe systems, valve manifolds and tank installations in different pharmaceutical and biotech facilities can be reduced by using multiport valves and complex multiport-based manifolds. Multiport solutions such as the Robolux valve from Bürkert Fluid Control Systems were developed with these high-purity installations in mind.

Based on diaphragm valve technology, this generation of patented valves combines independent dual-process switching functions – or “two seats” in a single body – with a single diaphragm and single actuator. The actuator has independent pistons – one for each seat – offering a compactly designed multiport valve that requires about 40 % less space than traditional valve manifolds designed with conventional diaphragm valves. Since less material is used in the body, it can be heated more quickly to the sterilisation temperature required to destroy microorganisms. A low internal volume and the elimination of dead space support faster cleaning and of course mean better process efficiency and higher product yield from the process. Continuing the benefit of minimum space requirement, the overall number of valves, T-pieces, weld joints and pipe runs has been greatly reduced. The result is an optimised footprint that enhances process efficiency, reduces installation and mainte-nance costs and minimises downtime.
Custom valve solutions
Robolux multiport valves with a nominal width of up to 50 mm are ideal for use in processes with large product quantities and accordingly large pipe diameters. Processing facilities with large tanks and piping systems need a lot of space. With multiport valve technology, these processes can be designed more efficiently with lower space requirements because one multiport valve replaces two conventional valves, including the T-piece.
Bürkert supports its customers in the design and implementation of the fluid part of their processes. Experienced hygienic processing experts design the valves and manifolds required based on individual customer requirements. Up to five Robolux valves can be mounted on one block. “In designing the system, we take into account factors such as the media flow direction and flow paths, self-draining and angles of inclination as well as overall geometric specifications relating to the maximum dimensions and connection positions. This is only possible in very close cooperation with the customer”, Alexander Equit, sales engineer at Bürkert Fluid Control Systems, explains. His team does more than just select and deliver the required valves. “We cooperate with the customer to determine how we can optimise the process, then develop the valve solutions so that they fit perfectly”. Occasionally, the design of the manifolds has to be modified to generate optimal fluid properties. If necessary, 3D models of the solutions are delivered to support the design process. “Of course, standard valves from the catalogue are also suitable for less complex processes. However, that is generally less than optimal. With customised modifications, on the other hand, we can always optimise the process”, Equit adds. “To do this, we do not necessarily have to be familiar with all the details of the entire production process. The individual components of the valve manifolds and their functions are sufficient”.
Cleanability
The cleanability of a pipe system is influenced by dead space volumes and the application of the xD rule. Currently, industry is still satisfied with the 3D rule. Its consistent application ensures sufficient flushing for many processes. The dead legs are only completely flushed and cleaned if their length is less than three times the diameter of the main pipe. Johannes Eichert comments: “It is not usually possible to consistently implement the 3D rule when arranging complex configurations with conventional valves; the goal of any plant operator and planning engineer is to remain well below the requirements of this rule”. The ideal solution would be to achieve the 1D rule – something the Robolux valve solutions are now capable of. The internal volume of the valves and/or valve manifolds is significantly smaller than in conventional valve solutions and there is no dead volume inside them. Eichert continues enthusiastically: “If we weld four conventional DN 15 diaphragm valves in a typical steam cross configuration, we have an internal volume of 90 ml held in the pipe section between the four valve seats. If we enhance the solution by using a standard valve block, we can reduce the internal volume to 50 ml while if we replace the stand-ard block with the Robolux valve, the total inner space volume is only 22 ml. Robolux valves therefore minimise not only the required installation space but also the time and the amount of flushing agent needed – with greatly improved cleanability. Robolux tank bottom valves ensure entirely new properties, such as the elimination of branch lines and contamination on the bottom of the tank – depending on their use as a switching, sampling or CIP/SIP valve.
Corrosion prevention
The cleanability of the pipes and valve manifolds is also extremely important for another reason: improper flow through the body can result in corrosion, which is a serious problem in production facilities. Cleaning or replacing the corroded equipment entails great expense and lengthy downtimes. The use of Robolux valve interfaces can effectively prevent corrosion. “We make sure that all valve interface areas are well flushed. This is confirmed by means of riboflavin or uranine tests at our in-house test facility that allow us to simulate the actual operating conditions”, says Alexander Equit.
Process availability
Valve interfaces must meet high standards to guarantee reliable processes, yet remain flexible for different applications. Robolux valves can provide a double block-and-bleed function to prevent the steam used to sterilise the parallel line from contaminating the product and vice versa; this is achieved by fitting a relief valve in-between the two seats. Multiport valve bodies genuinely enable the effective implementation of many complex applications. For example, parallel operation is possible with a Robolux DFP (Double Flow Path) interface, which increases the overall availability of the plant and saves production time.
The valves can act as a reliable sterile barrier in the fermentation process; a solution using two actuators and two diaphragms provides the function of a steam barrier with four connections and four seats, replacing four conventional valves with single actuators as well as the corresponding piping and connecting elements. In this way, Robolux multiport valves contribute significantly to cost reductions in hygienic processes.
Hall 1, Booth 107

  • Optionally pneumatically or manually controlled
  • Nominal widths from DIN DN08 to ISO DN 50
  • Three actuator and diaphragm sizes: RV50 / RV70 / RV110
  • Operating pressure from 0 to 10 bar
  • Body materials: 1.4435 stainless steel (316L), Hastelloy, titanium, PVDF or PP
  • Diaphragms: EPDM, PTFE, PFA/EPDM, FKM, silicone, Technoflon PFR91
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