Pharmaceutical Industry
The pharmaceutical sector relies on precise, contamination-free flow control. Valve failures in this industry can compromise product quality, regulatory compliance, and patient safety.
Our services ensure hygienic process valves operate at peak performance.
Common Valve Issues in the Pharmaceutical Industry – Challenges We Solve Daily
In pharmaceutical manufacturing, precision, sterility, and consistency are non-negotiable. Valves are used throughout critical applications like dosing, filtration, CIP (Clean-in-Place), and WFI (Water for Injection) systems — and when one fails, it can halt production, risk contamination, or lead to costly batch rejections.
At Valve Repair, we understand the unique challenges the pharmaceutical sector faces. Our repair solutions are tailored to maintain hygienic design standards, ensure regulatory compliance, and get production lines back online quickly without compromising product integrity.
Here’s a deeper look into the most common valve issues in pharmaceutical environments — and how we address them:
Wear and Tear from Aggressive Cleaning Chemicals
Pharmaceutical facilities rely heavily on CIP and SIP (Sterilise-in-Place) processes, which often use aggressive chemicals such as caustic soda, nitric acid, peracetic acid, and high-temperature steam. These can degrade seals, corrode metal components, and weaken elastomers over time — even those rated for hygienic use.
Signs of chemical wear include:
Embrittled or swollen O-rings
Surface corrosion on valve internals
Cracking or warping of valve seats
Reduced response times in actuated valves
How We Help:
We replace damaged components with FDA- and USP VI-approved elastomers and plastics like EPDM, PTFE, and silicone. Where applicable, we re-polish internal surfaces to restore sanitary finishes, and upgrade materials for greater resistance against chemical attack in future CIP cycles.
On-Site & Off-Site Options – Whether you need emergency field service or full workshop refurbishment, we offer flexible solutions to suit your operation.
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On-Site & Off-Site Options – Whether you need emergency field service or full workshop refurbishment, we offer flexible solutions to suit your operation. /
Malfunctioning Control Valves Affecting Dosing Accuracy
Control valves are vital for precise regulation of flow, pressure, and dosing in pharmaceutical manufacturing — especially during blending, filling, and ingredient handling. If they start sticking, drifting, or delivering inconsistent results, the entire batch can be affected.
Causes of dosing inaccuracy include:
Worn actuator components
Sensor feedback failure
Seat leakage or stem misalignment
Improper valve tuning or calibration
How We Help:
We conduct a full functionality check and recalibration of the valve and its actuator. This includes positioner testing, valve stroking, and seal replacement. Where required, we retrofit modern control equipment and ensure precise responsiveness — so your process lines meet both output and quality targets.
Specialist Parts Sourcing – We track down OEM or compatible components fast, even for obsolete or hard-to-find valves.
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Specialist Parts Sourcing – We track down OEM or compatible components fast, even for obsolete or hard-to-find valves. /
Seized Valves Due to Crystallisation and Product Buildup
Valves in pharmaceutical systems often handle high-purity fluids and chemical compounds that can crystallise when stagnant or exposed to air, particularly in lines that aren’t flushed correctly. This can lead to valves becoming blocked or seized, posing a risk to product flow and system pressure.
Crystallisation issues are common with:
Sugar-based solutions
Saline and buffer solutions
APIs (Active Pharmaceutical Ingredients)
Cooling and solvent systems
How We Help:
We mechanically and chemically clean affected valves, removing all traces of crystallisation and buildup. In cases of repeated blockages, we recommend changes to valve geometry or internals, or add purge and drain points to help flush the system post-operation. We also review materials to ensure they resist deposit formation.
End-to-End Support – From initial diagnostics to post-repair testing, we handle the entire process under one roof.
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End-to-End Support – From initial diagnostics to post-repair testing, we handle the entire process under one roof. /
Leaks Compromising Sterile Production Environments
In sterile environments, even minor leaks are unacceptable. A single droplet escaping from a valve can compromise the cleanroom classification, lead to microbial contamination, or disrupt the pressure differentials required in controlled zones.
Leak causes can include:
Failed O-rings or diaphragms
Micro-cracks in stainless steel welds
Improper torqueing during installation
Surface imperfections on sealing faces