Author: Rob Hamm

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Autoclave Control System Upgrades

autoclave control system upgrades

Outdated Autoclave Control System?

As autoclaves age, their control system ages as well. Many components of the autoclave are correctly categorized as wear items, such as valves and gaskets. Consistent evaluation and replacement of these components extends autoclave longevity and prevents maintenance issues from accumulating. While not a high-wear item, the control system of an autoclave can quickly become obsolete as the speed of technological and hardware advancements increases. Control system obsolescence may not sound like a significant problem, but consider:

Troubleshooting Autoclave Control System Issues

Outdated board-based machines are complex, limiting diagnostic and troubleshooting. If the motherboard manufacturer no longer provides support or replacement parts, any issue can render the machine inoperable. Modern control systems provide flexible and easy troubleshooting options as insurance against extended downtime events.

System Updates Increase Functionality

Nearly all digital devices that exist today have annual or semi-annual updates, which deliver increased functionality and features. For autoclaves, these updates improve control, customization, and archiving of user login functionality, data storage, cycle parameters, and global parameters.

Control Upgrades vs. Rebuilds

Control Upgrades

When the chamber and mechanical systems are in good condition,
a control-only replacement is recommended.

Control Rebuilds

A complete control rebuild is recommended when the chamber is in
good condition but mechanical and control system components need
replacing. If the chamber is beyond usable life, a new autoclave is required.

What to Expect With a Control System Upgrade or Rebuild

Whether a control upgrade or rebuild is completed on your autoclave, value add features ensure you receive the assets and resources necessary to operate your autoclave control. Beta Star’s use of non-proprietary parts on new equipment extends to upgrades, which reduces supply chain issues and lifetime cost-of-ownership. Upgrading a control system provides contemporary, industry-standard software with optional Beta Connect capability. Included in each autoclave are:

  • Custom Drawings: provide guidance for continual maintenance of the autoclave. Each drawing package is customized to the upgrade with a P&ID, electrical drawings, and the pneumatic manifold drawing when applicable.
  • Operations Manuals: we equip customers with the tools to ensure proper use and functionality of upgraded autoclaves. Along with the Operators Manual and Maintenance Schedule, we include a custom P&ID and electrical schematics.
  • Testing Documentation: when requested by the customer, we turnover Site Acceptance Testing (SAT) Documentation with optional execution by Beta Star technicians.
  • Custom Fascia/Enclosure: with careful analysis of each facility, we incorporate custom fascia panels and enclosure systems into each project to give a professional look with cleanable surfaces.

Beta Star’s talented team can perform control system upgrades on nearly every autoclave, regardless of manufacturer. To read more about Control System Upgrades and Rebuilds, download the PDF here.

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Autoclave Manufacturer: Door Gasket

How the machining process during the autoclave manufacturing impacts door gasket life.

For many who are in the process of considering an autoclave manufacturer, there is often little thought put to the actual manufacturing process. Instead, the focus is typically centered around the PLC control system, HMI, and service technicians. To be fair, these components of an autoclave purchase are important as the PLC and HMI operate as the brain of the autoclave with service technicians operating as the doctor whose task is to keep the autoclave running effectively and efficiently. However, one of the many components of the manufacturing process that must be considered is how machining the door gasket grooves, completed during the autoclave manufacturing process, impacts gasket longevity.

autoclave manufacturer completing gasket groove machining
Autoclave Manufacturing: Machining the Gasket Groove

In the manufacturing process, the gasket groove is cut into the door plate with a CNC machine with exact precision and tolerances measured in hundredths of an inch. The manufacturing process welds the ASME vessel (aka the autoclave chamber) to the door plate before the gasket groove(s) are cut into the door(s) plates. For small autoclaves, such as the 20” x 20” and 26” x 26” chamber sizes, nearly all autoclave manufacturers are capable of following the aforementioned process with machining centers that have the capability to cut door plates with those dimensions. For larger autoclaves, many manufacturers are not capable of following the same manufacturing process because of the limitations of their CNC machines. Instead, this part of the manufacturing process is reversed. The gasket groove is machined into the door plate first, and then the door plate is welded to the chamber.

Why does this matter in how I use my autoclave?

The reversal of the process opens the door gasket groove to subtle warping caused by welding the door plate to the autoclave chamber. As stated above, machining centers cut precise gasket grooves with tolerances down to hundredths of an inch. During the manufacturing process the accuracy of the gasket groove is one of, if not the biggest, predictor of gasket performance and longevity. With even subtle warping during the welding process, a pre-cut gasket groove can warp enough to cause faster degradation of the door gasket.

In the long-term, subtle yet additional degradation of the gasket caused by a slightly inaccurate gasket groove can cause premature gasket failure. Over the lifespan of an autoclave this would increase cost-of-ownership and create additional downtime events caused by gasket failure. Based on feedback from service technicians across the country, gasket life cycle can be cut by 50%. Costs could vary significantly depending on the size of the autoclave door, but the costs could equate to hundreds of dollars per year in unnecessary costs.

At Beta Star, machining centers are capable of machining all of the autoclave chamber sizes after door plate and chamber welding has been completed. This includes the largest chamber we’ve ever manufactured on a 64” wide x 92” height x 96” depth autoclave. By partnering with Beta Star, you can reduce gasket lifespan issues that come from manufacturing. 

autoclave door gasket inspection
Inspecting an Autoclave Door Gasket

More Autoclave Manufacturer Topics to Know

For more information about what to consider when selecting an autoclave manufacturer, visit the Autoclave Manufacturer post or any of the subtopics listed below:

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Autoclave Manufacturer: Customization

How working with a Custom Autoclave Manufacturer can help you with autoclave projects in existing buildings.

Whether you need vivarium autoclaves for your animal-related research facility or standard laboratory sterilization equipment, you may run into the option of buying a prefabricated unit or having your equipment custom-made. In a few respects, working with a custom autoclave manufacturer can be more advantageous if you are in an existing building than buying standard pieces. 

Cost-Efficiency for Specialty Autoclave Applications

Working with a custom autoclave manufacturer specialized in customized equipment delivers cost efficiencies for specialty autoclave applications. While you can find quite a few standard autoclaves with the most expected features, these units may not always cater specifically to your building or operation. In addition, opting to have a new autoclave retrofitted with additional features may not always be the most cost-effective option.

Instead, you are far better working with an engineer from a custom autoclave manufacturer to design the unit around your needs and with the features that coincide with daily use within your building. For example, if you need an autoclave with split bulk sterilizers (see illustration below), unique cycling capabilities, and a ventilation system that connects to your existing ventilation outlet points, a customized unit can be designed from the ground up. Therefore, post-manufacturing reconfigurations and adjustments will not be involved, and you can spend less to get the equipment you need. 

Get Larger Sterilization Equipment Manufactured and Installed, in Spite of Constraints in an Existing Building 

Certain autoclave projects have specific challenges that can only be efficiently addressed through engineering a customized piece of equipment. For example, if a company needs a large autoclave and operates from an existing, multistory building, buying a prefabricated unit can bring along hard-to-overcome quandaries. Many of these challenges will come into play during the installation process, such as: 

  • Elevator weight capacity restrictions or size limitations 
  • Restrictive hallway layouts that prevent adequate maneuverability of the equipment 
  • Doorway width and height limitations 
  • Problems with creating an adequately sized pit for installation

These types of challenges are hard to avoid in an existing building and can dramatically increase project costs. With our expertise in a custom approach, we developed the Split Bulk Sterilizer to eliminate all of the issues previously defined. While Beta Star does manufacture some standard sizes in batch lots, such as the LSII 20-inch by 20-inch or the 26-inch by 26-inch by 39-inch, our larger sizes are custom-made. 

Take Advantage of Custom Autoclave Manufacturing with a Streamlined Approach

Our integration with R-V Industries here at Beta Star Life Science Equipment has given new life to our manufacturing processes. R-V Industries actually specializes in custom manufacturing, and we’ve streamlined our own operations to coincide. When you opt for our services as your custom autoclave manufacturer, we provide: 

  • Engineering flexibility to get clients the autoclave sterilizers they need 
  • Carefully thought-out manufacturing plans utilizing the valuable insight of industry engineers 
  • Timely project efficiency with our in-house project scheduling department to ensure efficiency
  • A dedicated project management team to support client updates throughout the manufacturing process

We pride ourselves on delivering sterilization equipment that can suit even the most unique floorplans, usage objectives, or layouts. To find out more about our custom manufacturing processes, reach out to us. 

More Autoclave Manufacturer Topics to Know

For more information about what to consider when selecting an autoclave manufacturer, visit the Autoclave Manufacturer post or any of the subtopics listed below: