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Automated fluidics solutions for machines in the pharmaceutical industry
Developing, producing and installing machines for sterile environments requires a wealth of specialist knowledge, for example in the manufacture of pharmaceutical products. You are faced with the challenge of meeting the very high quality standards of the pharmaceutical industry and at the same time effectively managing your own company. Find out how Bürkert can support you in all project phases and develop automation solutions for you that offer your customer real added value – even in international projects
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Conventional fluidics solutions and their weaknesses
Precisely controlling and distributing the different media in production processes is one of the most demanding tasks facing pharmaceutical industry machinery. Nevertheless, the construction and start-up of the skids must be as economical and efficient as possible.
Media preparation
Goods delivery
Valve with conventional forged steel valve body
Pharmaceutical product manufacturers expect machines to have low operational costs, for example thanks to reduced steam requirements or minimised spare parts costs. Energy-efficient skids can cut production costs and reduce carbon footprints this way.
Intelligent components enable ongoing diagnostics of active units. The goal: ensure high process reliability and fast error identification. It’s a requirement that is increasingly in demand. The implementation of appropriate wiring and piping schemes for decentralised solutions can take a lot of time and effort.
The development and implementation of new pharmaceutical skids is complex, time-consuming and can quickly become cost-intensive. Modular solutions or individual systems can not only minimise the complexity of machine planning and parts procurement but also accelerate production times.
Traceability is essential for machines in pharmaceutical plants. All components require appropriate certificates. Production times and methods for parts need to be documented in order to carry out meaningful quality control. GMP and ASME-BPE guidelines also require traceability.
Demand for machines and equipment for pharmaceutical production is increasing on the international market. For you as a machine and plant manufacturer, this means: You have to involve all stakeholders in relevant processes and constantly keep them informed – a comprehensive and time-consuming task.
How Bürkert solutions intelligently and efficiently control sterile processes
Unique expertise in fluidics and automation solutions
Bürkert accompanies you in the development, production and installation of machines for the pharmaceutical industry, whether you manufacture in series or individually customise solutions to meet the needs of your customers. In addition to technologically mature components and systems for sterile fluidic processes – for example, customised block solutions, hygienic diaphragm valves and sensors as well as systems with critical properties including cleanability, high reliability and traceability – we also provide you with objective support in selecting the appropriate automation solutions.
Due to optimised geometries in our diaphragm valve bodies, flow coefficients are up to 35% higher than the industry average. This results in lower air pressure to move fluids through the valves as well as longer diaphragm service life. It also means smaller pumps that consume less energy are sufficient.
This also applies to sterile processes. Decentralised automation solutions from Bürkert are compatible with all common communication protocols and help with rapid fault identification, feature permanent diagnostics and provide predictive machine maintenance. The automation solutions are easy to install and enable quick start-up.
The production date is easily readable on the Bürkert diaphragms. This ensures transparency and traceability for quality control and machine servicing. The right time to replace a diaphragm depends on where it is used and the demands placed upon it. Bürkert is also happy to support you with the exchange.
Bürkert is a reliable and efficient partner for handling national and international pharmaceutical projects. This includes not only coordinating the various project planning groups but also optimising purchasing processes by combining multiple product packages.
Modular solutions reduce the complexity of a machine and shorten the production time of a skid. Assembling machines using modules creates great potential for savings, from ordering the components before production all the way to maintenance during operation.
Thanks to Bürkert’s “tube valve body” solution, your customers’ machines can run productively for longer periods. This is because the Bürkert solution (shown in blue in the graphic) cools down more quickly before cleaning or sterilisation and heats up again more quickly afterwards. Why? Bürkert solutions have less dead weight and thus less thermal mass than conventional forged steel valve bodies.
How Bürkert solutions save you and your customers money
Bürkert diaphragm valves with tube valve bodies are manufactured in a particularly material-saving way. As a result, they are lighter and have less thermal mass than conventional valves.
Example calculation: Thanks to the lightweight design of the “tube valve body”, you save energy and thus operating costs
In this calculation we take a medium-sized pharmaceutical plant that is to be newly built. Type 2031 valves with pneumatic control in various DNs (according to ASME or DN ISO) are required for controlling media in sterile environments. Below we compare the respective weight of a valve with forged body with that of a comparable “tube valve body”.
Forged steel valve body
Tube valve body
Difference
Number of valves in the project
Total weight reduction
In particular, the weight reduction of 4.5 t and 1.96 t due to the lower valve mass results in the following advantages:
lower operating costs due to faster heating and cooling times – here using the example of a sterilisation process
possible savings in freight and handling costs.
Bürkert
Conventional solution
Steam sterilising Air-cooled
Your partner for international projects
Planning and implementing new pharmaceutical systems and processes is a complex and expensive task. New processes or machines can be simplified and made more cost-effective by improving communications and collaborating with an experienced solutions provider. Coordinating the different project design groups and optimising purchasing processes by combining multiple product packages makes Bürkert the perfect partner for pharmaceutical projects.
Designing and building new pharmaceutical processes is a complex and expensive task. New processes or skids can be simplified and made more cost-effective by improving communication and working with an experienced solutions provider. By coordinating the different project design groups and optimising the purchasing process by combining a number of product packages, Bürkert are the perfect partner for pharmaceutical projects.
Find more interesting information on the topic here
Flow measurement in pharmaceutical applications such as WFI (water for injection) or CIP (clean in place)... and meet with our experts in a webinar. Practical examples will show how the SAW technology can be used to gain filling time, improve quality and reduce maintenance efforts.
Topic:Improving safety in pharmaceutical production with hygienic flow measurement
