Vaccine manufacturer solves mobile skid clogging problem with Bioflex Ultra

In a vaccine manufacturing process, sodium hydroxide is pumped from a mobile skid via suction and delivery hoses.

Could Bioflex Ultra provide solution to the long term condensation issues this company was facing?

Bioflex Ultra solves long term condensation problem
Puddling causing a slip hazard resulting in health and safety concerns

A world-leading biotechnology plant in Singapore were using a jacketed bioreactor (S.U.B) that came with pre-existing flexible hoses for the application of circulating thermofluid at 5C. However this process can experience temperatures of the thermofluid to as low as -40C up to +235C.

Using a competitor’s rubber hose during the process, the end user experienced issues with condensation droplets forming on the external rubber cover within the cleanroom environment, dripping onto the floor causing puddling. This led to health and safety concerns and highlighted by an internal audit.

To solve the issue the company was advised by a previous supplier, to add a fire jacket to the existing rubber hoses to try containing the condensation. This solution was also unsuccessful and hose damage near to the end connections was witnessed due to flex fatigue meaning further leaking occurred. Furthermore, the puddling issues caused by the condensation were still unsolved.

A third flexible hose alternative was designed specifically by a competitors engineering team to resolve these issues. However, the same problems occurred, end connections failed to be connected properly causing leaking, collapsing of the hose liner near the end connections occurred again and the original condensation issue resulting in the forming of puddles continued to be a long-term issue.

An employee working for the company who had previous experience working with Aflex PTFE hoses in other S.U.B applications, decided to contact Aflex for a solution.

Based on the customers’ requirements Aflex Hose provided our solution in the form of our flagship Bioflex Ultra GP, AS, SS braid along with 12mm closed-cell silicone insulation with an outer black EPDM rubber cover. Aflex also suggested our unique and PTFE lined “Hot-formed” Tri-clover end connection design.

Having gone through the testing stages Aflex successfully solved all major issues surrounding condensation, flexibility, life longevity and compliance with USP and FDA certification. Due to this success all existing competitor hoses at various S.U.B facilities are in the process of being replaced.