Customer-specific multiport valves result from the development of conventional valve configurations composed of 2/2-way and T-valves. They offer reduced dead space and clearance volume, go without an internal weld and are compact and easy to install. They are the most modern solution for the high requirements of the pharmaceutical industry. Complex processes and functionalities are still being implemented today, more than 15 years after the introduction of the first multiport valves, often with elaborately welded constructions. The valves, fittings and pipe components used require a large amount of mounting space and often include manual welding efforts on site that result in extensive validation.
Function
Multiport valves or M-blocks can combine the diverse functionality in a small space due to their individualised designs. Mixing, separating, routing, draining, feeding, isolating, safety functions, double shut-offs, cross connections and adjustment controls are all possible in addition to the control of individual paths. These individual functions are assigned very definite tasks depending upon the individual case: eg, sampling, connection to sterile steam (SIP), connection for cleaning medium (CIP), guarantee of a minimum flow. In addition, there are numerous other complex functions that can be implemented within the scope of process automation.
Consulting
Good valve technology begins in the project inception phase. The implementation of complex operational sequences requires compact valves that come in manifold designs. Gemü attaches great importance to customers obtaining a block that is optimised to their specific application, which may not necessarily be a standard catalogued solution. Numerous points need to be considered when designing and constructing M-blocks. Firstly, it is the application and process safety of the system into which the block is to be installed. Then the function of the block, the number, dimensions and function of the pipe connections; the number and size of the valve seats, the mounting position and draining direction of the block, the required space, the actuator type and function and the type of material must be specified.
Planning
The costs that potentially arise from errors in planning production systems in the pharmaceutical industry, justify increased planning time and expenditure. Delays and extra cost during validation, delayed start-ups, contaminated batches and changes to the system are only a few arguments in favour of detailed planning. M-blocks reduce process risks in the system. Experience over many years has shown that the costs for the removal of a faulty welding configuration and its belated replacement with an M-block technology exceed the initial procurement costs of an M-block several times. Thorough planning reduces the cost and delivery times associated with the blocks even further.
Partnership
In order to make processes safer, to increase the operational availability of the systems, and to reduce the lifecycle costs of a system within the framework of a total cost of ownership concept, more than 400 different designs and thousands of customer specific variations of multiport valves have been created at Gemü over the years. The company says it supports customers with ideas and initial designs from the conception phase. Next, the designs are constructively implemented into a 3D CAD system where they are optimised in close cooperation with the customer; afterwards they are machined using powerful CNC outfits. Every year, thousands of blocks ranging from 100 g up to 500 kg are manufactured in eight multi-axial processing centres.
Advantages of M-blocks:
* Individual, customer-specific construction and flexible design.
* Compact space requirements.
* Low hold-up volume, low wetted surface.
* Reduced dead spaces.
* Blocks are designed for optimal draining.
* CIP and SIP designs.
* Fewer, fittings, welds and X-ray examinations.
* Actuators and diaphragms from the Gemü advanced modular system can be used.
* Increased product safety.
* Reduced total cost of ownership.
For more information contact Keith Hedges, Gemü Valves Africa, +27 (0)11 462 7795, [email protected], www.gemue.de
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