Apache Stainless Blog

Processors serving food or hygienic industries have varying degrees of compliance requirements for custom vessels solutions.  The designation of "sanitary" has a wide range of definitions depending on the customer, the industry or the standard.  

Since Apache provides custom engineering and manufacturing, we reference these levels to guide conversations so the precise specifications for compliance and function are met. This video is a brief overview how Apache defines base, mid, and high level sanitary vessels.  

BASE LEVEL

Apache refers to a base level design as an entry-level, food grade, chemical and general use vessel. Base vessel sanitary construction is typically defined as continuous, crack and crevice-free welds. Fixtures are threaded, such as couplings and dip tubes, an may include ANSI flanges and Thermowells probes.  Base level tanks and vessels are pickle passivated and are manually cleaned after use. 

MID-LEVEL

In custom sanitary vessel discussions, Apache defines mid-level vessels as COP (clean-out-of-place) capable.  There is a higher level of finishing on the inside dimension for mid-level criteria, and the construction fixtures are all sanitary specified, like tri-clamp ferrules, tube connection, NA connects, and sight glasses for example. Processes and applications for mid-level sanitary tanks include columns, solvent tanks, collection, extraction, mixing and dispensing. 

HIGH LEVEL

The highest level of sanitary design vessels are designed with CIP (clean-in-place) processes.  The finishing on high-level vessels are smoothly polished to less than 32RA (roughness average) on the inside of the vessel.  The chemical finish is both nitric passivated and electropolished on high-level vessel designs.  Customized high-level sanitary tanks have electropolished sanitary fittings from tri-clamp ferrules, tube connects, to orbitally welded j-tubes, and polished internal coils.  Highly compliant and sanitary vessels are used for processing, WFI, R&D lab equipment, heat and cooling, and nutsche filtering. 

For more information into the criteria of sanitary vessels, please read "Guide to Sanitary Design for Custom Vessels", a quick-read guide to sanitary standards, construction and the effects on delivery and cost. 

Apache Stainless Equipment Corporation is a manufacturer of stainless equipment for a range of hygienic industries, including, food, beverage, biotechnology, pharmaceutical, cannabinoid, and life sciences.

A dedicated quality control and compliance team directs all tests, certificates and documents for all sanitary, ASME, and global standards.

ASME (American Society of Mechanical Engineers) is a leading developer of codes and standards in the mechanical engineering community. ASME code section VIII details mandatory rules regarding vessel design, including engineering, manufacturing, and testing of pressure vessels.   These standards enhance public safety and health as well as promote quality and innovation.  Here are the main parameters outlining ASME construction of pressure vessels with supporting ASME testing requirements.

Construction
Parameters such as wall thickness, material, and flange rating are determined by the application, including pressure, temperature, corrosion allowance, and fluid flow.  These conditions are calculated and reviewed/approved by the ASME inspector when required per code. Stainless, Hastelloy, AL6XN, duplex, and Inconel materials are ASME-approved materials for pressure vessel construction in the pharmaceutical, life sciences, and health-related industries, of which Apache is qualified to fabricate.

Welding
ASME standards also define the quality, type, and finishing of the welds. Head styles (ASME F&D, 80:10, 2:1 Elliptical), seams, nozzles, manways, and other components are designed per ASME Code. Applicable ASME Code welding procedures must be followed using certified ASME welders to maintain the structural integrity of an ASME pressure vessel. Welders must be certified to a qualified weld specification qualified per ASME code guidelines.

Safety Components
Gauges, valves, pressure outlets, and drainage are required safety components in ASME design pressure vessels. The proper selection of components and design is critically important to the safety and performance of the ASME vessel. The selection of safety components needs to be evaluated closely to define the required scope of supply.

Finishing
There is another ASME specification to ensure the quality and safety of parts used in pharmaceutical, bio-processing, and other industries requiring a hygienic vessel, called ASMP-BPE. BPE (Bio Processing Equipment Standard) specifies the surface finishes RA (roughness average) requirements and pickle passivation and electropolishing requirements.

Tests & Certification
There are significant testing, certifications, and documentation requirements for ASME compliance and satisfying the numerous customer requirements. Many require ASME inspection as well as a TOP (turnover packet).  Some ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT.

Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.