Saunders® Aseptic Diaphragm Valves

APPLICATIONS

The aseptic diaphragm valve is one of the most important control components in modern biopharmaceutical process systems. As the inventor of the diaphragm valve, Saunders has been a key player in the evolution of high purity valve technology. Beginning with the introduction of forged bodies and compact thermoplastic actuators, to modern solid compound and multi-port valve solutions, Saunders has long been a leader in aseptic valve technology.

DIAPHRAGM VALVE BODIES

Saunders offers bodies with weld and clamp ends to meet all global tube and pipe specifications. This includes OD tube, DIN, ISO, SMS, and schedule pipe. Standard body material for all forged bodies is stainless steel dual certified to 316L (ASTM A-182) and DIN 1.4435, with the additional requirement of controlled sulfur per ASME-BPE standard.

Cast bodies are available from 316L stainless steel. Bodies produced from alternate materials such as Hastelloy®, AL-6XN, 904L, and titanium are also available.

STANDARD 2-WAY BODIES

The standard 2-way valve body is the basic building block of diaphragm valve technology. Saunders 2-way forged bodies are manufactured from wrought 316L/1.4435 stainless steel bar with additional requirement of controlled sulfur per ASME-BPE standard.

The forging process results in a homogeneous surface that helps to eliminate porosity, inclusions, or shrinkage cavities. This surface is an ideal substrate for the high levels of mechanical and electropolished surfaces demanded by the clean processing industries to maintain sterility and optimize cleaning processes. Saunders forged bodies are manufactured to achieve low ferrite levels of less than 0.5% maximum. This reduces the potential for migration of oxides through a high purity water system.

Valve Body Features

The valve body is cavity-free and self-draining. It has full traceability to EN 10204 3.1 and ASME-BPE and serialized bodies for traceability. ASME-BPE bodies are marked in accordance with DT 11-1.

Forged Body Features

The forged body includes hash marks to indicate self drain angle. It has an integral weld and hygienic clamp ends along with controlled sulfur, 0.005-0.017% per ASME-BPE standard. It is certified to ASTM A-182 and DIN 1.4435 and is in full compliance with weld end tangent length as per DT-4.1.1 and with clamp end lay length per DT-4.4.1-1.

Custom valve types may be welded tandem valve assemblies, machined from solid block types or manifolds that incorporate both technologies.

Custom valve solutions include reduced wetted area to reduced dead legs, improved drainability, and reduced design envelope over arrangements using individual 2-way valve bodies. Custom valves are machined from solid bodies and offer increased security due to the elimination of internal fabrication welds.

TANDEM VALVES (STERILE ACCESS VALVES)

Tandem valves are designed to optimize drainability and meet process design requirements for minimum dead legs. A main valve is ported and a second access valve is welded to the main valve to create a tandem cluster.

MACHINED TANDEM VALVES

The machined tandem is a variation of the serial weir family. This machined-from-solid tandem valve type offers several advantages over the welded tandem.

VALVE MANIFOLD / CLUSTERS

Configuration of optimum process fabrication presents system designers with an ongoing challenge. Minimum space envelope, reduced hold up areas, reduced cost, and facilitating ease of installation are all key considerations.

ZERO DEAD LEG ‘TEE’ PATTERN RANGE

The Zero Static tee valve combines a single weir with a tee pattern body. This design eliminates the dead leg present when a 2-way valve is welded or clamped to a tee fitting and has become a biopharmaceutical standard. Essential for the elimination of dead legs in recirculating loops and designed to ease installation and validation, Saunders Zero Static tee valve enhances the integrity of critical systems.

POINT-OF-USE OPTIONS (ZEROSTATIC VALVE WITH ‘U’ BEND)

One of the most sensitive applications in a WFl loop is the use point valve. These valves represent the barrier between the safety of the recirculating loop and the potential hazards of the environment and function as the take off point for consumption of WFI. Valves for this application need the highest level of design security, integrity, and cleanliness. Saunders point-of-use valves are engineered to minimize dead areas and fully drain all associated tubing.

BIO-BLOCK VALVES

Bio-Block valves offer the foremost expression of aseptic diaphragm valve technology. Bio-Block designs are machined from solid bar or billet to create tee configurations or clusters of two or more weirs with shared chambers that result in a single design with reduced wetted area, optimum drainability, and the highest level of integrity.

Bio-Block Compound Solutions

Custom Bio-Block valves can be designed to create the most compact, minimum dead-leg options for unique piping challenges. Bio-Block Compound Solutions can replace welded clusters, manifolds, and valve/fitting combinations.

Multi-Port Diverter Valves - Zero Dead Leg Options

The family of multiport valves includes the diverter valve range. These valves include 2-way diverters on through to clusters that have up to eight outlets.

Tank Bottom Valves

The Saunders tank bottom valve incorporates the performance and features of a diaphragm valve into a machined from solid tank outlet design. These valves are free from fabrication welds and dead legs, enhancing structural integrity, and reducing the potential for process contamination. The absence of dead legs improves drainability and facilitates effective mixing.

Sample valves, purge valves, and ports are easily incorporated into the tank bottom design to achieve the desired performance.