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Case Study: Use of Ball Valves in Food Processing – Hygienic Flow Control That Delivers Performance

Industry: Food & Beverage (Dairy)
Application: Pasteurized Milk Transfer & Cleaning-in-Place (CIP) Lines
Operating Conditions: 80°C – 120°C, Clean water, steam, milk, and caustic solution
Valve Type: SS316L Sanitary Ball Valve with Clamp Ends
Compliance: 3A Sanitary, FDA Seals, WRAS-Approved Materials
Client Location: Pune, Maharashtra, India
Supplied By: Perfect Engineers

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Background

A mid-sized dairy facility in Pune producing pasteurized milk and flavored beverages needed a flow control solution that could:

Handle frequent clean-in-place (CIP) cycles
Prevent contamination or bacterial buildup
Withstand exposure to milk, steam, water, and caustic solutions
Maintain a leak-proof seal in both hot and cold conditions
Comply with food safety certifications (FDA, 3A, WRAS)

Their existing butterfly valves were experiencing product leakage, hard-to-clean areas, and downtime during CIP operations.

Our Hygienic Valve Solution

Product Supplied

SS316L Sanitary Ball Valves (Full Bore)
Tri-Clamp End Connection for tool-less cleaning
FDA & WRAS-certified PTFE + Silicone Seals
Blowout-proof stem + Anti-static device
ISO 5211 pad for future actuation
Pressure rating: PN25
Temperature rating: Up to 150°C

Installed Valve Applications

Pasteurized milk transfer from holding tank to filling line
CIP solution diversion in alkali rinse system
Hot water/steam shut-off for sanitization loops
Sugar syrup line control in flavored beverage preparation

Key Challenges

Challenge	Observations
Bacterial Risk	Dead zones in old valve design
Frequent Cleaning	CIP pressure affected sealing of old valves
Valve Downtime	Needed full disassembly to clean
Regulatory Compliance	No traceability or FDA seals on previous valves
Automation Compatibility	Future PLC upgrades required actuator support

Results & Performance Benefits

Impact Area	Result Delivered
Hygiene & Safety	100% compliance with food-grade requirements
Product Wastage	Reduced by 90%—leak-proof shut-off
Cleaning Efficiency	CIP time reduced by 40%
Valve Lifecycle	Over 18 months of maintenance-free operation
Plant Uptime	Improved by 25% with no valve-related stoppages
Automation Readiness	ISO 5211 pad supports future upgrades

Contact Us for Pricing & OEM Support

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+91-9004860491

E-mail

[email protected]

Website

www.perfectqrc.com

Key Technical Advantages

Full bore design = no flow restriction for viscous liquids
Tri-clamp connection = tool-less maintenance
Smooth, electropolished body = no contamination zones
3-piece construction = inline servicing
FDA-compliant silicone and PTFE = safe for food, dairy, and beverages

Why Food Processors Choose Perfect Engineers

Full bore SS316L sanitary ball valves
Custom fabrication for dairy, beverage & pharma plants
Valves with 3A, FDA, WRAS and ISO 5211 standards
Bulk supply and OEM branding for plant builders
Steam-rated, fire-safe, and CIP/SIP-compatible models

FAQs – Ball Valves in Food Processing

Why are ball valves preferred over butterfly valves in CIP lines?

Ball valves offer zero leakage, full bore flow, and are easier to clean inline. They also support higher pressure/temperature ratings.

What certifications are important for food valves?

At minimum:

FDA-compliant elastomers
3A Sanitary Standard
WRAS or EU 1935/2004 food contact compliance

Can these valves handle carbonation or sugar syrups?

Yes—SS316L valves with PTFE or TFM seats handle carbonated or high-viscosity fluids effectively.

Can I automate a food-grade ball valve?

Yes—our valves come with ISO 5211 actuator interface for pneumatic or electric control.

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