Clever design halves the number of valves required

Burkert has supplied a Robolux valve system for use on a machine that fills asthma inhaler cartridges for a multinational pharmaceutical company. The unique Robolux design has enabled Burkert to reduce the costs of the system drastically, by cutting the valve requirement from eight diaphragm valves down to four. In addition, because Burkert's integrated design has only one block - compared to two for competitive units - there are fewer welded connections for the customer to make, which reduces installation time and validation costs; the integrated design also means that internal volumes are smaller, eliminating deadlegs and maximising sterility.

The design specification for the asthma inhaler project called for a valve system that would reduce the internal volume and the number of pipe connections on the filling and cleaning lines of the machine. It projected a total of eight aseptic diaphragm valves per machine to carry out the control of the filling and cleaning lines.

Burkert was competing against two other suppliers, both of which were offering conventional diaphragm valves arranged in two blocks that were welded together. This meant that there were 12 welds in total on the blocks.

Complete package

However, Burkert's offering differed in that it used the company's innovative Type 2034 Robolux diaphragm valves mounted on a single customised stainless steel block; this was the first new application for the product in the UK. In addition, Burkert also offered a Type 5470 manifold block to pilot the valve block - providing a complete system from one supplier, which was something that neither of its competitors could do.

The modular nature of the 2034 Robolux design meant that Burkert was able to present its proposed design to the customer within two weeks - as against six weeks for the competitor designs. Moreover, the competitive offerings both required two separate valve blocks, whereas the Burkert proposal required only one.

As a result of its innovative design of the Burkert Robolux double-weir valve system, and because the design has only one block, the number of valves required has been cut from eight to four, so there are fewer welded connections for the customer to make. Moreover, the layout of the 2034 and the valve block means that internal volumes in the Burkert system are said to be smaller than the competitors' offerings. As a result, medium losses are reduced, sterility is easier to ensure and maintain, and the risk of cross-contamination is greatly reduced.

About Robolux valves

Robolux valves are supplied with either manual or pneumatic actuators in sizes from 1/4inch to 2inch (DN4-50). They are manufactured with a choice of body types: 316-L stainless steel, ultra-pure polypropylene, polypropylene USP V1 and PVDF (polyvinyl-difluoride). The valves also offer a wide range of diaphragm materials to suit all types of media, including EPDM, FKM, PFA/ EPDM, PTFE, silicone and PFR91.

In addition, Robolux valves hold all major certifications: FDA, CE, USP V, USP VI, ATEX, 3.1 and are therefore applicable worldwide. They are used successfully in chromatography and also for a wider range of applications including CIP/SIP processes, UF/MF filtration and filling and formulation.

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