Multi-Port Valves - Don't Go For Less
Customer-specific multi-port valves result from the further development of conventional valve configurations, composed of 2/2-way valves and T-valves. They offer markedly reduced dead space and clearance volume, they go without an internal weld, and they are more compact and easier to install. They are the most modern solution to meet the high requirements of the pharmaceutical industry.
Complex processes and functionalities are still being implemented today, more than 15 years after the introduction of the first multi-port valves into the market, often with elaborately welded constructions. The valves, fittings and pipe components used require a large amount of space, serious mounting and often manual welding efforts on site, and result in an extensive validation. Let's not even mention their high hold-up volume and large dead spaces when complying with the customary 6D or 3D rules.
Function
Multi-port valves or M-blocks can combine the most diverse functions in a very small space due to their individual designs: Mixing, separating, routing, draining, feeding, isolating. Safety functions, double shut-offs, cross connections and adjustment controls are also possible in addition to the control of individual paths. These individual functions are assigned very definite tasks depending upon the individual case: e.g. sampling, connection to sterile steam (SIP), connection for cleaning medium (CIP), guarantee of a minimum flow. There are, in addition, numerous complex functions within the scope of process automation.
Consulting
Good planning of valve technology already begins in the project phase. The implementation of complex operational sequences requires compact valves that come in manifold designs. GEMÜ attaches great importance to customers obtaining a block that is optimized to their specific application, and not some standard solution out of a catalog. Numerous points are to be considered when designing and constructing M-blocks. In the first place is the application and process safety of the system into which the block is to be installed. The function of the block; the number, dimensions and function of the pipe connections; the number and size of the valve seats; the mounting position and draining direction of the block; the required space; the actuator type and function; and the type of material are to be specified.
Planning
"Failing to plan is planning to fail". The costs that could arise from errors in the planning of production systems in the pharmaceutical industry justify increased planning time and expenditure. Delays and extra cost during validation, delayed startups, contaminated batches and later changes to the system are only a few arguments in favor of such planning. M-blocks reduce process risks in the system. Experience over many years has shown that the costs for the removal of a faulty welding configuration and its belated replacement with an M-block, exceed the high procurement costs of an M-block several times. At the same time, timely and thorough planning reduces extra cost and delivery times to a minimum.
Partnership
In order to make processes safer, to increase the operational availability of the systems, and to reduce the lifecycle costs of a system within the framework of a total cost of ownership concept, more than 400 different designs and thousands of customer-specific variations of multi-port valves have been created at GEMÜ over the years. GEMÜ supports its customers with ideas and initial designs starting from the development phase.
Next, the designs are constructively implemented into the 3D CAD system, they are adjusted in close cooperation with the customer, and afterwards they are processed in a powerful machine outfit. Every year, thousands of blocks ranging from 100 g up to 500 kg per unit are manufactured in eight multiaxial processing centers. Every day, up to five new customer-specific block variants, on average, are generated in the design center. Anything you can imagine or anything we develop together with you becomes a reality at GEMÜ.
Advantages of M-blocks
Complex processes and functionalities are still being implemented today, more than 15 years after the introduction of the first multi-port valves into the market, often with elaborately welded constructions. The valves, fittings and pipe components used require a large amount of space, serious mounting and often manual welding efforts on site, and result in an extensive validation. Let's not even mention their high hold-up volume and large dead spaces when complying with the customary 6D or 3D rules.
Function
Multi-port valves or M-blocks can combine the most diverse functions in a very small space due to their individual designs: Mixing, separating, routing, draining, feeding, isolating. Safety functions, double shut-offs, cross connections and adjustment controls are also possible in addition to the control of individual paths. These individual functions are assigned very definite tasks depending upon the individual case: e.g. sampling, connection to sterile steam (SIP), connection for cleaning medium (CIP), guarantee of a minimum flow. There are, in addition, numerous complex functions within the scope of process automation.
Consulting
Good planning of valve technology already begins in the project phase. The implementation of complex operational sequences requires compact valves that come in manifold designs. GEMÜ attaches great importance to customers obtaining a block that is optimized to their specific application, and not some standard solution out of a catalog. Numerous points are to be considered when designing and constructing M-blocks. In the first place is the application and process safety of the system into which the block is to be installed. The function of the block; the number, dimensions and function of the pipe connections; the number and size of the valve seats; the mounting position and draining direction of the block; the required space; the actuator type and function; and the type of material are to be specified.
Planning
"Failing to plan is planning to fail". The costs that could arise from errors in the planning of production systems in the pharmaceutical industry justify increased planning time and expenditure. Delays and extra cost during validation, delayed startups, contaminated batches and later changes to the system are only a few arguments in favor of such planning. M-blocks reduce process risks in the system. Experience over many years has shown that the costs for the removal of a faulty welding configuration and its belated replacement with an M-block, exceed the high procurement costs of an M-block several times. At the same time, timely and thorough planning reduces extra cost and delivery times to a minimum.
Partnership
In order to make processes safer, to increase the operational availability of the systems, and to reduce the lifecycle costs of a system within the framework of a total cost of ownership concept, more than 400 different designs and thousands of customer-specific variations of multi-port valves have been created at GEMÜ over the years. GEMÜ supports its customers with ideas and initial designs starting from the development phase.
Next, the designs are constructively implemented into the 3D CAD system, they are adjusted in close cooperation with the customer, and afterwards they are processed in a powerful machine outfit. Every year, thousands of blocks ranging from 100 g up to 500 kg per unit are manufactured in eight multiaxial processing centers. Every day, up to five new customer-specific block variants, on average, are generated in the design center. Anything you can imagine or anything we develop together with you becomes a reality at GEMÜ.
Advantages of M-blocks
- Individual, customer-specific construction and very flexible design
- Compact design – space required is small
- Low hold-up volume, low wetted surface
- Markedly reduced dead spaces
- All blocks are designed to have optimum draining
- Machined from a single material block
- CIP and SIP-suitable design
- No internal welds --> shorter cleaning times
- Less fittings, welds and X-ray examinations
- Standard welded ends for orbital welding, as well as clamps, etc.
- Actuators and diaphragms from the proven GEMÜ advanced modular system can be used
- Shortened and simple validation
- Clearly increased product safety
- Reduced total cost of ownership
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