Newly developed valves with automation inside do not require complicated or lengthy installation. This helps pharmaceutical companies launch their products faster.
As competition increases in the pharmaceutical industry, getting a new product to market quicker and keeping it there longer is essential. Each time a new product is developed, a new production plant needs to be built or an existing one refitted; and the whole planning, commissioning and construction process has to be completed as quickly as possible.
Within this process, each component of the plant, such as valves, must be designed to meet these needs. Today’s valve designers must consider integrated automation and compact design, as well as simpler and quicker installation and commissioning for their clients.
Integrated valve
A traditional valve comprises three parts, which are assembled using valve-specific adapter kits to obtain a functional valve, an actuator and the valve’s position feedback.
A modern trend in valve design employs ‘automation inside’, which considerably speeds up the installation and set-up process. By integrating the automation functions into the valve actuator, time and money can be saved on labour and fittings.
Gemü has developed a single-unit valve, the Gemü 651, which can be installed easily and is ready for operation in no time thanks to its new Speed-AP function.
Automation inside is also driven by the high aseptic requirements set by the US FDA for the pharmaceutical and biotechnology industries. A compact valve actuator is much easier to clean as it has fewer critical areas, connections and edges.
Simpler and safer
Single-unit valves minimise the potential for leaks and errors resulting from faulty connection or assembly, while logistics and material management are simplified.
Maintenance and servicing of diaphragm valves are easier with the new initialisation function. After a diaphragm change, a remote electrical signal starts initialisation. The valve then moves to its various positions following a pre-programmed routine and detects the new end positions. This only takes a few minutes and can simultaneously take place in the entire plant without manual intervention by service staff. The time-consuming manual setting of conventional electrical position indicators working with microswitches or sensors is no longer necessary. Furthermore, as there is no need to remove the housing cover, the protection class that has been specified and tested at works is maintained.
Automated valves work well with the AS-Interface fieldbus system. In addition to simple electrical installation, such a system offers detailed monitoring and diagnostic possibilities, immunity to interference and an easy link-up to other fieldbus systems such as Profibus-DP.
The Gemü 651 piston-operated valve is designed for sterile applications and is available in ‘open/closed’ or ‘position control’ versions. The valve has normally-closed, normally-open and double-acting control functions. Due to its compact design it can be used in very restricted spaces, such as in valve batteries or as a component in multi-port valve blocks. All body types from the Gemü modular diaphragm valve system (2/2 way, T, tank wall and tank bottom, and multi-port valve bodies) can be used.
The valve design was developed to meet FDA, EHEDG and GMP guidelines and recommendations. The standard version has M5 control air connectors in the flow direction with optional 90°-rotated connectors. The mounting position and flow direction are immaterial.
The valve has CIP/SIP cleaning and sterilising capabilities, while clearly visible coloured LEDs indicate the status of the operating voltage, current function mode and valve position. The pneumatic actuator housing is made of stainless steel, and the automation module housing of PP (polypropylene). The protection class is IP 65 and electrical connection is via a standard five-pin plug.