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Category Archive: Sanitary Equipment

Tag Archive: Sanitary Equipment

  1. Maple Syrup Producers Use Heat Exchangers to Improve Production

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    The Science and Innovation Behind Maple Syrup Production

    Maple syrup is a beloved topping for pancakes, waffles, and countless other treats. While its rich, sweet flavor remains timeless, the process of making maple syrup is constantly evolving. Producers have a limited window each year to harvest sap and transform it into syrup, making efficiency and innovation key to success.

    The Fleeting Sugaring Season

    Sugaring season begins when winter transitions into spring, creating warm days and freezing nights. This temperature fluctuation causes sap to flow from maple trees, a process that continues until nighttime temperatures remain above freezing and buds begin to form. Once the sap becomes bitter, the season comes to an end.

    Since weather patterns shift annually, sugaring season can vary in duration. An early spring may lead to an early start, while a sudden warm spell can shorten the season significantly. Because of this unpredictability, syrup producers must work quickly and efficiently to maximize their yield.

    Speeding Up the Sap Production Process

    To make the most of sugaring season, producers have developed innovative methods to speed up and refine the syrup-making process. One such approach involves using indirect heat systems to accelerate evaporation. Some producers employ steam-craft technology to pre-boil the sap, significantly reducing the time needed for evaporation compared to traditional direct-heat methods.

    Many producers also use sanitary shell and tube heat exchangers to pasteurize syrup, making it less viscous and easier to bottle while removing potential contaminants. Another widely adopted method is reverse osmosis (RO), which concentrates the sap before it enters the evaporator. RO technology improves efficiency by reducing the time and energy needed for evaporation, allowing producers to decrease fuel consumption while maintaining syrup quality.

    Saving Energy During Syrup Production

    Since syrup production is consolidated into a several-week-long sprint, condensed operations demand high energy spend. While more syrup producers are utilizing RO technology, there are other ways producers can save energy.

    A large amount of water needs to be removed from sap to make syrup. Because of this, the syrup-making process gives off incredible amounts of steam. The steam released provides a convenient and free heat source that producers are beginning to take advantage of.

    By installing a shell and tube heat exchanger, syrup manufacturers can capture the heat lost to rising steam and use it to preheat the sap before it reaches the evaporator. Like RO, this process will reduce the amount of time the sap needs to spend in the evaporator before it reaches the desired consistency.

    This mechanism was perfected in 1974 by George Raithby of the University of Waterloo in Ontario. Prior to Raithby’s development, the use of any equipment above the evaporator would compromise the final product because rising steam would condense on the metal surface and drip back into the open pans of syrup. Raithby used a shell and tube heat exchanger with a drip pan installed beneath it to collect the condensate. Inside the tubes, the sap could be heated from a starting temperature of about 40 degrees Fahrenheit to around 190 degrees Fahrenheit before it reaches the evaporator.

    Today, modern stainless steel heat exchangers continue to enhance durability and performance in maple syrup production.

    Making the Most of Sugaring Season

    Sugaring season may be short, but its impact is long-lasting for both producers and syrup lovers alike. Innovations in heat transfer technology, reverse osmosis, and energy efficiency help producers optimize their operations and ensure a steady supply of high-quality syrup. If you’re looking to improve your syrup production process, consider investing in a shell and tube heat exchanger. Reach out to the engineers at Enerquip to explore how this technology can enhance your operation.

     

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  2. Growing Demand for Frozen Vegetables Calls for Advanced Manufacturing Equipment

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    Vegetables are a key part of any healthy diet, providing essential nutrients that are hard to find in other foods. Whether paired with a meal or enjoyed on their own, they’re a delicious and versatile choice.

    However, fresh vegetables come with some challenges. They’re often seasonal, which means they can be expensive and less flavorful when bought out of season. Plus, they have a short shelf life, limiting how long you can enjoy them.

    Fortunately, frozen vegetables offer a great solution. Available year-round at almost any grocery store, frozen veggies are convenient, last longer, and are usually just as tasty and nutritious as fresh ones. They’re often more affordable too, making them a go-to option for many families.

    Consumers Like it Cold

    The frozen vegetable industry continues to grow. According to a 2024 report from Grand View Research, the global frozen food market (frozen fruits, vegetables, ready meals) was valued at over $194 billion in 2023, with a projected annual growth rate of 5.4% from 2024 to 2030. This surge is driven by consumers’ focus on healthy eating and the convenience of quick-prep meals, especially in today’s fast-paced world.

    Frozen veggies are a perfect fit for modern lifestyles. As more people aim to eat healthier, they’re seeking out time-saving options that don’t compromise nutrition. The rise of home cooking trends, including meal-prep and freezer-friendly recipes, has made frozen vegetables a pantry essential. Additionally, improved access to refrigeration and freezing technology across the globe has opened up the market to more consumers, particularly in developing countries.

    How Frozen Vegetables are Made

    Have you ever noticed labels boasting that veggies were frozen just hours after harvesting? It’s true, but there’s more to the story. Before vegetables are frozen, they go through a crucial step called blanching.

    Blanching involves briefly heating the vegetables in hot water or steam, which helps to kill bacteria and deactivate enzymes that could spoil the food. This process also preserves the color, flavor, and texture, ensuring the veggies taste fresh when you cook them later. After blanching, the vegetables are quickly cooled, sorted, and frozen.

    Turning Up the Heat

    Blanching needs to be done precisely to ensure the vegetables maintain their quality. Typically, vegetables are heated to around 212°F for a quick blanch or 150°F for a warm blanch, depending on the vegetable. After blanching, they’re cooled to around 100°F.

    Manufacturers rely on efficient equipment to heat and cool the vegetables quickly while minimizing energy use. One of the best tools for this process is a shell and tube heat exchanger. These systems can be used to control the temperature of the heating medium for blanching and recover heat energy lost during the process. This heat recovery can reduce energy consumption, saving manufacturers money while keeping the process sustainable.

    Improving Your Vegetable Processing Operation

    Frozen vegetable manufacturers need to focus on efficiency, quality, and safety. At Enerquip, we specialize in designing and fabricating shell and tube heat exchangers for almost any process. Talk to our team of engineers today to find the perfect solution for your vegetable processing operation.

     

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  3. Honey Warming Prevents Crystallization

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    The Sweet Science of Honey Processing: Preventing Crystallization

    Honey is a popular sweetener many people often use while baking, in teas and as a topping on toast or ice cream. When thinking of honey, most envision an amber-colored, sticky liquid that is easily, if slowly, poured from a bottle. This is the most popular form and the state in which honey producers strive to keep their product.

    As many people know, honey is a substance created by bees. The bees extract nectar, or sugars, from flowers to transform into honey in their hives. The substance is therefore essentially a sugar mixture, composed primarily of fructose and glucose, according to Serious Eats. These sugars can cause the honey to crystallize over time, making it appear cloudy and thick.

    The speed at which honey crystallizes depends on several factors, including storage conditions, the types of flowers the bees sourced nectar from, and the treatment of the honey before it reaches store shelves.

    Keeping Out Crystals

    To prevent early crystallization, honey producers often use a heating and filtering process. Heating the honey serves multiple purposes:

    1. Dissolving Sugar Crystals: Heating helps dissolve any existing sugar crystals, preventing them from multiplying.
    2. Thinning the Honey: Warm honey is thinner and easier to strain, allowing for the removal of particles like pollen and bee parts.
    3. Removing Particles: Straining out particles reduces the number of surfaces on which sugar crystals can form, further preventing crystallization.

    For optimal results, honey should be heated to 160°F for a short period. A stainless steel shell and tube heat exchanger is ideal for this process. The heating element, such as water, evenly warms the honey to the desired temperature, ensuring consistent treatment and preventing early crystallization.

    For information on how shell and tube heat exchangers can benefit your food production business, contact the experts at Enerquip.

     

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  4. Process Cooling: The Salsa Cooling Challenge

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    A custom heat exchanger design allows a salsa manufacturer to effectively complete process cooling of the product and expeditiously clean-in-place between batches and shifts.

    California-based Southwest Thermal Technology was approached by one of its OEM customers to provide a shell-and-tube cooler to chill a client’s salsa prior to bottling. The request was more challenging than it sounds.

    The Challenge

    Because of the viscosity of the salsa — around 2,000 cP while warm and much thicker at 9,165 cP when cooled — turbulent flow was extremely difficult to achieve in the tubes of a shell-and-tube heat exchanger. The viscous salsa hindered efficient heat transfer. Typically, this situation is addressed by using a heat exchanger with more surface area while using a high volume of cooling water on the shell side of the heat exchanger. Such a design could achieve process cooling from 200 to 120°F (93 to 49°C).

    Southwest Thermal Technology wondered whether a more compact solution was possible. That’s when they reached out to Enerquip.

    After reviewing the problem, the engineers at Enerquip first considered a single, large heat exchanger that would perform well thermally. But the single large exchanger would be difficult to clean with the salsa maker’s clean-in-place (CIP) system. Typically, CIP works best when the cleaning solution can be circulated at 5 ft/sec or more. In a single, large exchanger, this would not be achievable.

    Of course, in food production environments, it is crucial to keep process equipment like shell-and-tube heat exchangers clean and sanitary. Regular CIP cleaning takes place between batches or shifts. This prevents cross-contamination of different products between batches and prevents unwanted bacterial growth that could contaminate food products.

    A New Approach

    The design team at Enerquip then developed a new approach. Process cooling of the salsa would occur by flowing through three smaller heat exchangers stacked in series. The salsa would pass from one heat exchanger to the next traveling through a sanitary jumper, which connected the outlet of the first exchanger to the inlet of the second exchanger, and likewise for the second-to-third exchanger connection. Meanwhile, the cooling water would flow counter-current from shell to shell, starting in the third exchanger, flowing through the second exchanger, and finally through the shell of the first unit.

    To realize this process cooling solution, three unique shell designs were created. They allowed the connecting flanges between each shell to be bolted together for the chilled water flow. Tube-side connections included an additional CIP connection on the first bonnet for the inlet and on the last bonnet for the outlet. CIP flow through the other bonnets used the jumper connections for the salsa to further reduce the piping costs and complexity.

    Enerquip Salsa Coolers – Stacked Set

    This design allowed for more efficient process cooling. In addition, the reduced exchanger size allowed the units to be cleaned effectively using the customer’s CIP system at 5 ft/sec flow through the tubes.

    Enerquip Salsa Cooler Enerquip Salsa Cooler

    Because of the acidity of the salsa, the salsa maker opted to use a higher stainless alloy for the tubes and other product-contact surfaces of the exchangers. While more expensive, super-austenitic stainless steel is more resistant to corrosion from acids and cleaning solutions.

    Another benefit of the three smaller, stacked exchangers over one larger exchanger was risk avoidance. If there was ever a tube failure in the single large exchanger, the customer would potentially be shut down completely during a repair, and the entire tube chest would need to be replaced. This would take months to achieve due to the lead-time on super-austenitic tubing. By using three smaller shell-and-tube heat exchangers in series, the salsa maker has equipment redundancy. Any of the units can be temporarily bypassed if there were a tube failure. Replacement of a smaller tube chest would be less than the cost of a single, larger one.

    Through this approach, the salsa maker was able to get more consistent process cooling and meet all the sanitary requirements for cleaning their equipment. As an added benefit, the company gained flexibility and redundancy while minimizing the risk of costly downtime.

    Article published in Process Cooling magazine: July 2019.

    Jim Peterson, Enerquip Sales Engineer

    Article Author: Jim Peterson, Enerquip Sales Engineer

    sales@enerquip.com

  5. Five Important Qualities to Look for in Pharmaceutical Process Equipment

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    In recent decades, there has been a notable surge in regulations and oversight pertaining to pharmaceutical manufacturers. This heightened scrutiny has resulted in stricter design specifications for process equipment. Notably, pharma-grade shell and tube heat exchangers must adhere to stringent criteria. These criteria include ease of cleaning, compatibility with appropriate heat transfer fluids, resistance to contamination and corrosion, and overall reliability. Let’s delve further into why these factors are crucial.

    Five Necessary Features of Pharma-Grade Shell and Tube Heat Exchangers

    1. Easily Cleaned

    Pharmaceutical products must be as pure as possible, and one step in achieving maximum purity is using clean equipment. Residue remaining from the previous batch or product type can taint the next round of product.

    Any amount of product left behind that could feasibly be removed through normal cleaning methods should not be present in equipment before production begins, according to the U.S. Food & Drug Administration’s Current Good Manufacturing Practices.

    Instruments that test for cleanliness today are highly accurate, able to detect even tiny amounts of residue. As such, it’s not always feasible to clean equipment to the point where absolutely no amount of previous product is detected. However, it’s always best to clean as thoroughly as possible.

    Choosing equipment that’s easily cleaned is a good step toward ensuring product batches are as pure as possible. Certain configurations of shell and tube heat exchangers are more easily cleaned than others. For example, straight tube exchangers are often easier to clean than U-tube style exchangers because there are no bends to maneuver around.

    Drainability can affect how easy it is to clean a shell and tube heat exchanger. If it’s hard to get the last ounces of liquid out of an exchanger, it’s harder to rid the equipment of all traces of the fluids. Exchangers that are designed to promote drainability, such as those offered by Enerquip, are best for this purpose.

    2.Compatible Heat Transfer Fluid

    Your equipment needs to be compatible with the substances that will pass through it – both on the tube side and the shell side. The heat transfer fluid used plays a large role in how effective the heating or cooling process is, as well as how well the equipment will hold up in time.

    Fluids that aren’t effective for heat transfer will require a longer process time and more energy to run. Additionally, fluids that can be corrosive can cause equipment to wear out faster. Some fluids are flammable, creating potential risks in the work environment if products or equipment are mishandled.

    3. Leak-Free

    Enerquip Double Tubesheet DesignNo manufacturer or equipment operator wants to have leaks. But for pharmaceutical processing equipment, leaks are particularly troublesome. Leaks create the possibility of product contamination, as well as corrosion or other chemical reactions that may occur when process and utility fluids mix.

    One way to reduce the risk of leaks is with a fully welded tubesheet. Another method to minimize the risk of leaks – or at least the negative impacts of them – is to design an external leak path to prevent any possible leakage from interacting with the fluid on the opposite side of the exchanger.

    Shell and tube heat exchangers constructed with double tube sheets are designed to drain any leakage away from the exchanger to minimize the chances of cross-contamination. At the same time, the operator is alerted to the problem so he or she can address it promptly.

    4. Resistant to Contamination and Corrosion

    Equipment used to create any product should not pose any risk of contamination. However, avoiding contamination means different things for different industries, processes and products.

    To minimize the risk of contamination as much as possible, equipment used for pharmaceutical production should be pharma-grade. Enerquip’s high purity exchangers are ideal for this industry. Our knowledgeable heat exchanger experts have ample experience fabricating shell and tube heat exchangers for pharmaceutical purposes, and are even used by companies like Bristol-Myers Squibb, Pfizer and Unilever.

    Corrosion-resistant materials also help to lower the risk of product contamination. Corrosion can be caused by chemical or physical processes, and the residue that emerges through this process can be reactive or can put the purity of the product at risk. Stainless steel and stainless-steel alloys are highly resistant to corrosion, making them smart choices for pharmaceutical construction.

    5. Highly Dependable

    All manufacturers, regardless of industry, strive to reduce or eliminate downtime. Every minute of downtime has a real impact on the company’s bottom line.

    Choosing reliable equipment is one of the most effective ways to reduce downtime. The less frequently equipment requires maintenance or spare parts, the more often it’s contributing to your facility’s production.

    Enerquip prides itself on fabricating equipment that is long-lasting and can be counted on. To learn more about choosing the right pharmaceutical process equipment for your facility, contact us today.

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    Editor’s note: This content was originally published in 2018 but was updated in 2024.

  6. Exchanger System Helps Food Packager Put the Soup On

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    A Chicago liquid-foods packager found themselves in a make-or-break moment. A major customer was ready to hand them a lucrative soup-packaging contract—but only if they could guarantee one thing: every batch had to be cooled from 198°F (92°C) to exactly 77°F (25°C) before it hit the packaging line.

    That precise temperature wasn’t the only challenge. The packager needed a system that could handle different soup recipes, meet strict food-grade sanitation rules, and fit into a footprint about the size of a walk-in closet—14 feet by 6 feet, under a 12-foot ceiling. Oh, and it had to keep utility costs in check by using cooling tower water whenever possible.

    No pressure, right?

    The Challenge: Cooling, Cleanability, and a Tight Fit

    Different soups meant different thermal properties, so the system had to be flexible. It also needed to be easy to clean between batches. If any leftovers lingered, flavors could mix or bacteria could grow. Accuracy mattered, too. If the soup was too warm, it could spoil. Too cool, and the containers could sweat, causing labels to slide off. Not exactly ideal for a product on shelves.

    The space issue made everything trickier. The heat exchangers had to meet strict 3-A sanitary standards while also staying compact, cleanable, and efficient.

    First Attempt: Two Large Exchangers, One Big Problem

    The packager’s engineering partner first proposed a simple setup: two large, straight-tube shell-and-tube exchangers in series. The first would knock down the temperature using cooling tower water. The second would finish the job using a 45°F (7°C) glycol/water mix from a chiller. Both were inclined for draining and built with davit swing arms for easier inspection.

    On paper, it looked clean and straightforward. In practice, two issues popped up quickly.

    1. The Temperature Cross Problem

    Because cooling tower water entered at around 70°F (21°C), it warmed up to about 120°F (49°C) inside the shell. That meant the soup couldn’t get any cooler than that in the first stage. The second exchanger—and the chiller—would have to do nearly all the heavy lifting. That meant higher energy use and a bigger, pricier chiller.

    2. Cleaning Bottlenecks

    The exchangers could be backflushed, but hitting the recommended 5 ft/sec cleaning velocity wasn’t possible with the packager’s 200-gallon-per-minute CIP system. Achieving proper cleaning would have required a system nearly eight times larger. Not exactly realistic.

    These limitations pushed the team back to the drawing board.

    Rethinking the System: Smaller Exchangers, Bigger Benefits

    To solve the cleaning issue, the team took a different approach: reduce the tube field size. That meant shrinking the exchanger diameter from 24 inches to 6 inches. With less area in each unit, more units were needed overall—six exchangers for the cooling-tower stage and two for the glycol/chiller stage.

    This redesign fixed more than just cleaning.

    Better Heat Transfer: Fewer tubes meant higher product velocity, which boosted cooling performance.

    No More Temperature Cross: Each small exchanger got its own stream of fresh cooling tower water. That prevented the warm-up effect that stopped the first system from reaching lower temperatures. In winter, when cooling tower water dropped below 70°F, the packager could skip the chiller altogether and cool the soup with ambient water alone.

    Easier Cleaning and Sanitation: The smaller units reached the needed CIP velocity and were easier to polish to 3-A standards. The lighter bonnets also made teardown and inspection much simpler.

    The Final Layout: A Stacked, Flexible, Space-Saving System

    The eight exchangers were mounted on a custom rack, with room left to add two more if future recipes or batch sizes required extra cooling power. All units were pitched for draining and connected with easy-to-reach utilities and jumpers.

    Standardizing on smaller exchangers had bonus benefits:

    • Lower-cost spare parts

    • Readily available gaskets and clamps

    • Interchangeable components across all eight units

    Most importantly, the entire stacked system fit inside the tight footprint and stayed within the project budget.

    Results: A Cooler Process and a Hot Contract Win

    The redesigned cooling system delivered consistent, precise temperatures across multiple soup types. It checked every box: sanitary design, easy cleaning, lower utility costs, space efficiency, and room for future growth.

    With the cooling challenge solved, the packager secured the contract—and gained a more efficient process for years to come.

    If you’re facing tight specs, tight space, or a tight deadline, you don’t have to tackle it alone. Reach out to Enerquip, and let’s build the right solution together.

  7. Pharmaceutical Manufacturers Must Meet ASME-BPE Standards

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    Editor’s note: Content last updated 3/7/24

    In any industry, it’s important to have standards that lay out what consumers expect of the products created by manufacturers and define the processes by which these products can be created. Without standards, consumers may mistakenly purchase a subpar product that does not meet their expectations, leaves them frustrated and damages the manufacturer’s reputation.

    In certain industries, compliance with these standards is absolutely critical. In any market where end users are coming in direct contact with a product or ingesting it – like the food and beverage, dairy or pharmaceutical industries – manufacturers must take every step possible to ensure the final product meets consumer expectations and is safe to consume.

    To ensure that all products are high-quality, there are countless standards that govern many different industries. For example, fabricators of equipment for the dairy industry adhere to 3-A Sanitary Standards, created in the 1920s to ensure that all machinery that came in contact with milk and milk-based products created a sanitary environment.

    Pressing need for pharmaceutical standards

    Where the food, beverage, and dairy industries have excelled in having extensive rules and regulations regarding the environments in which products could be made, the pharmaceutical industry fell short. For many years, there was no 3-A equivalent for biopharma manufacturers that explained what sorts of materials could be used to make equipment or how that equipment needed to be treated or maintained.

    Enerquip Electropolish Finish

    Manufacturers filled the void in their own ways. Some created their own in-house standards to ensure their products would always be consistent. Many turned to the dairy industry’s 3-A standards and applied them to their pharmaceutical operations.

    Though sufficient to keep products sanitary, safe and consistent, the lack of a uniform standard weighed on the industry. After numerous requests, the American Society of Mechanical Engineers collaborated to come up with the ASME-BPE (Bioprocessing Equipment) Standard.

    The standard was first published in 1997 and updated several times since. With it, pharmaceutical manufacturers are better able to communicate their needs to equipment fabricators, collaborate with other companies and stay in line with the U.S. Food and Drug Administration’s policies and current good manufacturing practices.

    ASME-BPE related to heat exchangers

    The ASME-BPE standard covers a wide range of topics, but here are ten important parts related to shell and tube heat exchangers:

    1. Material selection: Heat exchangers should be constructed of materials that are compatible with the process fluid and cleaning solutions, and which meet the purity and quality requirements of the biopharmaceutical industry.
    2. Surface finish: The interior surfaces of heat exchangers should have a smooth, uniform finish that is resistant to corrosion and microbial growth.
    3. Welding and joining: The welding and joining techniques used in the construction of heat exchangers should meet the requirements of the ASME-BPE standard, including orbital welding, electropolishing, and passivation.
    4. Design and construction: Heat exchangers should be designed and constructed in accordance with the requirements of the ASME-BPE standard, including dimensional tolerances, material specifications, and surface finish requirements.
    5. Testing and inspection: Heat exchangers should undergo rigorous testing and inspection to ensure that they meet the quality and performance standards required by the biopharmaceutical industry.
    6. Cleanability: Heat exchangers should be designed and constructed to facilitate thorough cleaning and sterilization, with no dead spots or areas that are difficult to access.
    7. Surface finish measurement: The surface finish of heat exchangers should be measured using appropriate techniques, such as profilometry, to ensure that it meets the required standards.
    8. Gasket and seal materials: The gaskets and seals used in heat exchangers should be constructed of materials that are compatible with the process fluid and cleaning solutions, and which meet the purity and quality requirements of the biopharmaceutical industry.
    9. Pressure testing: Heat exchangers should undergo pressure testing to ensure that they can withstand the operating pressures and temperatures required by the biopharmaceutical process.
    10. Documentation: All aspects of the design, construction, and testing of heat exchangers should be fully documented, with detailed records of materials, processes, and inspections maintained for regulatory compliance and quality assurance purposes.

    Understanding your operation’s needs

    Your operation likely comprises multiple systems and units to produce various products, each with its own unique requirements and features.

    Certain sections of the standards will relate more closely to specific parts of your operation. For instance, your high-sensitivity processes require the strictest adherence to the standards since they come into direct contact with the product. Such processes need highly cleanable surfaces with many requiring electropolished finishes. It is important to choose appropriate materials for not only the interior surfaces but also exterior surfaces.

    In contrast, low-sensitivity processes do not come in contact with the product. Rather, they support the systems that do. Therefore, it is important to carefully fabricate low-sensitivity processes to ensure a sanitary environment. However, these processes do not need to be as high-grade as the ones that directly touch the final product, such as tank jacket systems.

    A seat at the ASME-BPE table

    Preferred equipment suppliers like Enerquip proactively participate in the ASME-BPE committee meetings to help shape the standards that apply to shell and tube heat exchangers. If your pharmaceutical manufacturing operations require new or upgraded shell and tube heat exchangers, we invite you to connect today.

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