In the aseptic production process, the most commonly used shut-off valve is the diaphragm valve, often referred to simply as a diaphragm valve. Its widespread use can be attributed to two main factors: its simple design and relatively low cost, which have made it the dominant choice in the industry for many years. While there are alternative valves, such as the bellows globe valve—also known as the bellows valve—the latter has not been able to challenge the diaphragm valve due to its significantly higher price, despite offering some technical advantages.
The long-standing competition between diaphragm and bellows valves in the aseptic process industry reflects their distinct strengths and limitations. For a long time, the diaphragm valve has maintained an advantage due to its ease of cleaning, disinfection, and cost-effectiveness. However, the variety of specifications available for bellows valves remains limited compared to diaphragm valves. Today, Tuchenhagen Vesta’s corrugated pipe valve aims to address this gap by offering a more versatile option that combines the benefits of both types.
One key consideration when using diaphragm valves in horizontal pipelines is proper installation. If not installed according to the manufacturer's instructions, diaphragm valves may fail to fully vent the media or experience operational issues. The installation angle varies depending on the type of diaphragm valve and the nominal flow rate, which can complicate the design and manufacturing of aseptic systems. This issue is particularly noticeable in T-type diaphragm valves. In contrast, Vesta bellows valves do not suffer from these problems. They ensure complete emptying without any "dead zones" during operation, maintaining tightness and allowing flexible installation methods.
In the medical and pharmaceutical industries, where aseptic processing equipment involves numerous horizontal and vertical pipes, the placement of valves is crucial. Bellows valves, like those from Vesta, are better suited for specific locations due to their compact size and compatibility with various piping configurations. Unlike T-type diaphragm valves, which can be costly to produce, bellows valves offer greater flexibility in connection and installation.
In fields such as medicine, food, and biotechnology, many valves require sterilization. Larger valves, like the Stericom series, often have fewer sterilization needs due to lower flow rates and smaller volumes. However, the new Vesta bellows valve, with its smaller volume and improved design, offers better performance in these scenarios compared to traditional diaphragm valves.
Equipment utilization is another important factor. The goal is to maximize the use of equipment throughout its lifecycle while minimizing downtime for maintenance. Diaphragm valves typically require periodic replacement of the diaphragm, which can be influenced by factors such as corrosion, temperature, pressure, and the frequency of opening and closing. These conditions can shorten the lifespan of the diaphragm, leading to increased maintenance costs and production interruptions. In contrast, PTFE bellows valves are less prone to wear and can operate continuously with minimal maintenance, making them a more reliable choice in aseptic environments.
The core component of the Vesta bellows valve is the cut-off bellows made from TFM1705 PTFE. This material is highly resistant to chemical corrosion and meets FDA regulations for perfluorocarbon resins. Its smooth surface (Ra ≤ 0.8 mm), excellent sealing properties, and large actuation range make it ideal for efficient CIP/SIP cleaning and sterilization processes. Over the past three years, this patented valve has gained significant market acceptance, proving its ability to effectively isolate the internal pipeline from external atmospheric conditions in aseptic systems.
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