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WFI circuit: Increasing security and saving operating costs with local control loops of valves and sensors

Water for injection (WFI) for the pharmaceutical industry requires special handling. Quality needs to be controlled and documented and flow velocities need to be measured and regulated so that purity and availability can be consistently guaranteed. The amounts of energy required for the production, distribution and storage of WFI result in significant operating costs. At the same time, environmental protection and sustainability are becoming increasingly important at many pharmaceutical companies. This makes the energy efficiency of a plant an important issue in the overall investment decision, a decision we are happy to help you with.

The challenges of WFI controls

WFI is a significant cost factor in the manufacture of medical products and must be used sparingly for both economic and ecological reasons. Imprecise measurement methods are counterproductive. There are a number of challenges that arise during the process:

Water treatment
WFI tank
Pump
Heat exchanger
WFI flow
Control valve for pharmaceutical applications
WFI extraction points
Coriolis flowmeter
WFI return flow
Ultrasonic clamp-on

The conventional solution and its weaknesses

Precisely controlling and monitoring the WFI loop with customised systems

Reliable and efficient solutions are required to maintain, regulate and document water quality and availability in your WFI circuit round the clock. This lets you quickly respond to deviations and avoid process failures or defective batches.

PLC
Water treatment: Monitoring water quality: Online and continuously – with Type 8905
Control valve Type 2103
WFI tank
Control valve Type 2105
Control valve Type 2104
Control valve Type 2104
Pump
WFI flow
Heat exchanger
FLOWave S Type 8098
FLOWave L Type 8098
FLOWave L Type 8098
Electromotive control valve Type 3363
WFI return flow

The advantages of Bürkert solutions in local control loops:

Specific consultation for customised control loops

We want to ease your workload and help find your ideal solution together. That is why Bürkert supports you from the individual design of the control loop to the selection and dimensioning of the valves required in the process – including actuator technologies – all the way through to the appropriate automation solution. This means you both accelerate processes and increase system efficiency and reduce planning, start-up and operating costs. We personally tend to the selection and, if needed, pre-installation of all necessary components (valves, drive technology, pipelines) in close coordination with you.

Grafik, die mit Icons und Piktogrammen das Service-Spektrum eines Herstellers darstellt, von Analyse, Beratung, Auslegung, Komponenten/Systemen bis Inbetriebnahme

Use our valve variant calculator to determine which valve solution is right for your WFI circuit.

Ask our experts about the ideal layout of your control loop – with automation, too.

Less energy consumption with solenoid valve technology

Power is required to create compressed air, and this is a considerable cost factor. While conventional valve technology requires a continuous compressed air supply, Bürkert’s solenoid valve technology only used compressed air when the valve position is being changed. This reduces energy consumption considerably.

Movement
Compressed air consumption nozzle and flagger plate principle
Compressed air consumption Bürkert solenoid valve principle

Reducing operating costs with modern valve technology: Constant compressed air use in conventional valves adds up over a variety of valves and through the years.

In our sample calculation, you need 100 litres of compressed air per hour without regulation for the conventional solution. You can save on these with solenoid valve technology. Now calculate this over a period of 10 years, with 100% availability and across 30 devices, and you can save 28,000 € in this example by using less compressed air.

We have not included the costs of the low consumption of compressed air for the regulation of the Bürkert solution.

                            Conventional solution                               Bürkert solution

100 l per hour: Compressed air consumption without control action
0.1 € costs per Nm³ compressed air
10 years run time at 100% availability
Hours
Hours
10 years run time at 100% availability
0.1 € costs per Nm³ compressed air
30 devices
30 devices
876 € costs per device in 10 years
0 € costs per device in 10 years
0 € costs total
28,280 € costs total
0.0 l per hour: Compressed air consumption without control action
Chemical Resistance ChartChemical Resistance Chart

The Bürkert resistApp helps you identify compatible materials and compiles information for you about the chemical resistance of elastomers, plastics and metals for a large number of gaseous and liquid media.

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Christian Bürkert GmbH & Co. KG

Christian-Bürkert-Straße 13-17

D-74653 Ingelfingen, Germany

Telefon: +49 7940 10 0

Telefax: +49 7940 10-91 204

Do you have any questions? Don´t hesitate to contact us.

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