In aseptic production processes, the most commonly used shut-off valve is the diaphragm valve, often referred to simply as a diaphragm valve. The widespread use of this type of valve can be attributed to its simple design and cost-effectiveness, which have made it a dominant choice in the industry for many years. While there are alternative valves, such as the bellows globe valve, these have not been able to compete effectively due to their higher price. Although bellows valves offer certain technical advantages, like better sealing and reduced dead spaces, their limited availability and higher cost have kept them from becoming a mainstream option.
The competition between diaphragm valves and bellows valves has been ongoing in the aseptic process industry for decades. Diaphragm valves have long held an advantage because of their ease of cleaning, low cost, and simple structure. However, they do have limitations—especially when installed in horizontal pipelines, where improper orientation can lead to incomplete drainage or "emptying" issues. This problem is more pronounced in T-type diaphragm valves, making them less ideal for certain applications.
In contrast, Vesta bellows valves, such as the Tuchenhagen Vesta corrugated pipe valve, are designed to eliminate these issues. They ensure complete emptying of the media during operation, regardless of installation orientation. Their construction also avoids "dead corners," which helps maintain hygiene and tightness in aseptic systems. These valves can be installed in various configurations, offering greater flexibility in complex piping layouts commonly found in pharmaceutical and food processing equipment.
Moreover, bellows valves are generally more compatible with vertical piping installations, eliminating the need for additional fittings like 90° elbows. This makes them more efficient in terms of space and design. In addition, the smaller size and compact design of bellows valves provide better integration with piping systems, especially when dealing with smaller flow rates.
From a maintenance perspective, diaphragm valves require periodic replacement of the diaphragm, which can be costly and time-consuming. Over time, factors such as chemical corrosion, high-temperature cleaning, and mechanical stress can significantly reduce the lifespan of the diaphragm. On the other hand, bellows valves, particularly those made from materials like TFM1705 PTFE, are more durable and resistant to wear. They are less prone to damage from mechanical forces and offer longer service life, reducing downtime and maintenance costs.
The core component of the Vesta bellows valve is the cut-off bellows, made from high-quality TFM1705 PTFE. This material not only resists corrosion from various chemicals but also meets FDA standards for food and pharmaceutical applications. Its smooth surface (Ra ≤ 0.8 μm) ensures effective CIP/SIP cleaning, while its reliable sealing and large switching distance enhance performance in aseptic environments.
Since its introduction, the patented Vesta bellows valve has gained significant market acceptance. It provides a reliable solution for isolating the internal pipeline from external atmospheric conditions, ensuring the highest level of sterility in critical processes. With its combination of durability, efficiency, and compliance, it represents a strong alternative to traditional diaphragm valves in modern aseptic systems.
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