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Clever design increases diaphragm durability

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Author: Vulkan Verlag

Date: 30. May. 2020

In no other sector the validation processes, manufacturing guidelines and inspections are so strictly regulated as in the pharma and biotech industries. This is because people’s lives are ultimately at stake. Plant engineers, constructors and operators are confronted by ever more complex challenges. Under constant cost pressure, they must not only comply with strict guidelines, but also minimise risks and boost efficiency. In pharmaceutical processes, diaphragm valves are indispensable ingredients that guarantee hygiene by separating valuable media from the outside world. Diaphragm valves are used in many typical pharma applications: media preparation, fermentation, filtration, filling or clean utilities.
INTERFACES AND BODIES IMPROVED
Bürkert diaphragm valves can be assembled from a wide range of bodies, diaphragms and actuators to suit every application (Figure 1). The valve interfaces and forged bodies have now been further improved in terms of the design and interaction of individual components. The result is a range of diaphragm valves characterised by long-lasting, maintenance-friendly design while at the same time guaranteeing reliable and hygienic processes. With the new Tube Valve Body, Bürkert has already developed an innovative body, whose lightweight design saves energy during the heating phase and time during the cooling process. This makes processes sustainable and more productive. Now, the geometry of the 2-way forged bodies has also been optimised. A smooth edge radius on the body reduces the stress on the diaphragms, making them last longer.
LEAK-TIGHTNESS PROTECTS AGAINST CONTAMINATION
The design modification also improved the forged body from a hygienic perspective. An axial sealing lip on the diaphragm increases the compression. Leak-tightness has been improved in this way to prevent the ingress of media or foreign particles. As a result, the fluid is better protected against contamination. To improve the life time, the compressor contour for EPDM and PTFE diaphragms has also been modified. The overall design is now more flexible, the contact surface between diaphragm and compressor is greater, and the load distribution more even and smoother. The life time of the diaphragm can be further extended if, for a given diaphragm size, the spring force is reduced or a smaller actuator is used.
PRACTICAL TESTING: DIAPHRAGMS LAST UP TO 50 % LONGER
The durability of the diaphragms has been demonstrated in practical testing under the harshest conditions (Figure 2). Realistic SIP (Sterilisation in Place) conditions were simulated in an automated test system. Tested diaphragm valves were subjected to thousands of actuations in cycles of steam, vacuum and cold water. The test data confirms the improvements: The tested diaphragm lasted around 30 to 50 % longer than comparable products. Plant operators benefit from the extended life time because long-lasting diaphragms ensure more reliable plant operation. Apart from this, longer maintenance intervals enable further operation cost savings.
QUICK AND SAFE DIAPHRAGM REPLACEMENT
Bürkert diaphragm valves are easy to handle and can therefore be installed and maintained quickly and safely. The diaphragms are simple to replace, for example, if more stringent hygiene requirements must be fulfilled or if diaphragms with different characteristics are needed. Bayonet or threaded connections allow diaphragms to be removed from the actuator in just a few simple steps. The actuator is designed so that the compressor is automatically secured and cannot fall out when the diaphragm is replaced. This saves time and makes assembly and maintenance easy and safer.
IFAT 2018: Hall C1, Booth 427/526
ACHEMA 2018: Hall 11.1, Booth E62

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