Category Archives: Blog

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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Outdated Autoclave Control System?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Outdated board-based machines are complex, limiting diagnostic and troubleshooting.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.

Blog

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:

Blog

Autoclave Manufacturer: USA Single-Sourced

bulk autoclave built by a usa autoclave manufacturer

Why trusting a single-source, USA autoclave manufacturer for autoclave production matters.

When sourcing autoclaves for your operation, whether that be biopharmaceutical, laboratory-based, or otherwise, you will face a big decision. Should you work with a single-sourced USA autoclave manufacturer or opt for multi-sourced autoclaves.

Numerous advantages of working with a single-source autoclave manufacturer exist. Take a look at just a few of those benefits of relying on a U.S. single-source manufacturer for your much-needed equipment. 

Gain Better Control Over Lead Time

When you work with a single-source autoclave manufacturer, you gain more power over lead time with your equipment orders. Using a single-source manufacturer optimizes lead time because the manufacturer can effectively target and reduce four of the primary types of waste associated with lean manufacturing. For those unfamiliar, lean manufacturing always means reduced waste, optimized processes, and cut costs without an effect on productivity. The four types of waste that can be targeted by trusting a single-source manufacturer include: 

Transportation

Parts and materials will not be transported to and from various manufacturers where the risk of project schedule disruptions increases.

Motion

Autoclaves will not be subject to unnecessary movement which increases the likelihood of delays.

Waiting

Time waiting for equipment from other manufacturers will be reduced.

Over-Processing

Equipment (autoclave chambers and supporting components) will not require additional processing time that does not bring value. This includes quality processing that must occur between multiple manufacturers.

bulk autoclave built by a usa autoclave manufacturer
Bulk autoclave chamber

Reap the Advantages of Quality Control Oversight

When you are working with a single-source autoclave manufacturer, quality control oversight becomes a more uniform effort. You have equipment that is controlled by the QC oversight at just one location instead of multiple locations that may have differing QC processes. For example, you will always know what to expect with provided weld documentation because the same autoclave manufacturer was overseeing the quality of welding processes and weld procedure specifications. As an adage, when you work with a single source US autoclave manufacturer, you can easily determine if the manufacturer is Nuclear Quality Assurance (NQA-1) Certified.

Negate Customs and Geographical Issues

Covid-19 has impacted international manufacturing, trade, and global supply chains profoundly, and in more than one way. The pandemic brought out concerns of risk exposure between countries simply due to travel and the transport of supplies or goods. So much so that some countries temporarily restricted incoming shipments from offshore locations and halted shipments from their own countries completely. Many companies that were sourcing their manufactured supplies from offshore suppliers fell into precarious shortages that affected their ability to keep going.

Due to the eye-opening experience with Covid-19, more countries have begun to rely more on onshore supplies to thwart risks of interruption to their business or operation. According to Forbes, the reshoring of manufacturing efforts is bound to become more the norm in the coming months and years. When you work with a US autoclave manufacturer that operates as a single-source operation, overseas shortages, trade restrictions, and other problematic situations are less likely to affect your own operation.  

usa autoclave manufacturer, from raw plate to FAT
Every weld is completed at our Pennsylvania facility.

Choosing the Right USA Autoclave Manufacturer Makes the Difference 

In the end, a single-source autoclave manufacturer like Beta Star means you always get a quality, reliable product that can be customized to your standards. Even more important, you negate issues that can come along with international suppliers and wasted resources. To learn more about Beta Star Life Science Equipment and our capabilities, reach out to us for more information. 

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:

Article Sources

7 Wastes of Lean (Kanbanize.com): https://kanbanize.com/lean-management/value-waste/7-wastes-of-lean

Why Reshoring US Manufacturing Could be the Wave of the Future (Forbes.com): https://www.forbes.com/sites/forbesbusinesscouncil/2020/09/09/why-reshoring-us-manufacturing-could-be-the-wave-of-the-future/?sh=3b4283143bfc