Sanitary Manifolds & Hygienic Flow Distribution Systems (ASME BPE / DIN 11864)
In complex fluid processing lines, minimizing the number of welded joints and mechanical connections is critical to reducing contamination risk. Standard piping assemblies often create “dead legs”—stagnant zones where cleaning fluids cannot reach, leading to bacterial growth. Our Sanitary Manifolds solve this by consolidating multiple flow paths into a single, precision-machined block or welded assembly. Designed for the Pharmaceutical and Food & Beverage sectors, these Hygienic Fluid Distribution Manifolds optimize system footprint, ensure 100% drainability during CIP cycles, and eliminate the leakage points common in multi-component assemblies.
- Material: 316L (1.4404) with < 0.5% Ferrite.
- Finish: Electropolished ID Ra < 0.38μm (SF1).
- Design: Zero dead-leg; slope-optimized drainage.
- Connections: Tri-Clamp, DIN 11864, or Orbital Weld.
- Testing: 100% Boroscope & Hydrostatic tested.
- Compliance: FDA 21 CFR & ASME BPE.
Technical Specifications
Product Name
Sanitary Manifold / Hygienic Distribution Header
Design Standards
ASME BPE-2022, 3-A Sanitary Standards 85-03, EHEDG Guidelines
Base Materials
SS316L (1.4404 / 1.4435); Hastelloy C22 (upon request)
Tolerance Class
Product Grade A (d≤M24 and l≤10d), Product Grade B (>M24)
Connection Types
Tri-Clamp (ISO 2852), DIN 11864-1/-2, SMS 1145, Butt Weld (Tube OD)
Valve Integration
Integrated Diaphragm Valves (GEMÜ/Saunders compatible), Butterfly, or Seat Valves
Surface Finish (Internal)
Mechanical Polish (Ra 0.5μm); Electropolished (Ra 0.38μm /SF1)
Pressure Ratings
Vacuum to 10 Bar (Standard); High Pressure (up to 25 Bar) available
Reduced Hold-Up Volume: Traditional piping loops utilize Tees and Reducers that increase the total system volume and surface area. Our Block Machined Sanitary Manifolds significantly reduce the internal wetted area and hold-up volume. This directly lowers the cost of expensive WFI (Water for Injection) and reduces the volume of product loss during changeovers.
Elimination of Dead Legs: By integrating valve seats directly into the manifold body or using “close-coupled” branches, we adhere to the ASME BPE 2D Rule (Branch length < 2x Pipe Diameter). This ensures that turbulence from the main flow path effectively scours the branch, preventing biofilm formation common in deep T-pieces.
Simplified Installation & Validation: A single pre-fabricated Sanitary Multi-Port Manifold replaces dozens of individual welds and clamps. This drastically reduces on-site orbital welding time and simplifies the IQ/OQ (Installation/Operation Qualification) validation process, as the entire assembly comes with a comprehensive documentation package (Weld Logs, Material Heat Numbers).
Standard dimensions for a Tri-Clamp Distribution Manifold (Main Run vs. Branch).
| Main Run Size (OD) | Branch Size (OD) | Port Spacing (C-C) [mm] | Total Length (L) [mm] | Connection Type |
| 1.5″ (38.1mm) | 1.0″ (25.4mm) | 120 | 400 | Tri-Clamp / Weld |
| 2.0″ (50.8mm) | 1.0″ (25.4mm) | 140 | 480 | Tri-Clamp / Weld |
| 2.0″ (50.8mm) | 1.5″ (38.1mm) | 150 | 520 | Tri-Clamp / Weld |
| 3.0″ (76.2mm) | 1.5″ (38.1mm) | 180 | 650 | Tri-Clamp / Weld |
| 3.0″ (76.2mm) | 2.0″ (50.8mm) | 200 | 720 | Tri-Clamp / Weld |
| 4.0″ (101.6mm) | 2.0″ (50.8mm) | 220 | 800 | Tri-Clamp / Weld |
Orientation for Drainage: Sanitary manifolds must be installed with a specific slope (typically 1/8″ per foot or 1%) to ensure gravity drainage. When installing horizontal manifolds, verify that the eccentric outlets are positioned at the bottom (6 o’clock) or that the main run is sloped towards the drain port to prevent pooling.
Gasket Compression: For Tri-Clamp Manifolds, ensure that all branch connections use gaskets of the same material batch. Differential compression between EPDM and PTFE can cause misalignment in rigid piping systems. Use torque-controlled clamps (3-5 Nm) to prevent gasket intrusion into the flow path.
Thermal Expansion: Long manifolds (e.g., >1 meter) in SIP (Steam-in-Place) systems will expand significantly. Do not rigidly fix both ends of the manifold. Use sliding pipe shoes or flexible hangers to accommodate thermal growth (approx. 1.6mm per meter per 100°C) and prevent stress fractures at the branch welds.
Related Products
FAQ
What is the difference between a "Pull-Tee" and a "Block" Sanitary Manifold?
A Pull-Tee Manifold is fabricated by mechanically pulling ports from a main tube and orbital welding extensions; it is lighter and cost-effective for general food distribution. A Block Manifold (Monoblock) is machined from a solid billet of stainless steel. It is more compact, has zero dead volume, and is preferred for critical Bio-Pharma applications despite higher cost.
How do you ensure the manifold is fully drainable?
We engineer our Sanitary Manifolds with specific slope angles and eccentric reductions. During installation, the engineer must verify the manifold is pitched towards the drain point. In block manifolds, the internal flow path is often machined with a built-in slope, allowing the exterior to remain level while the interior drains completely.
Can you customize the port spacing on the manifold?
Yes. Unlike cast components, our manifolds are custom fabricated. We can adjust the Center-to-Center (C-C) spacing to match your existing pump skids, valve clusters, or floor penetrations, ensuring a drop-in fit that eliminates the need for flexible hoses or field welding.
What surface finish is required for Pharmaceutical Manifolds?
For pharmaceutical applications (per ASME BPE), the standard requirement is an internal surface finish of Ra < 0.5μm (20μin), often designated as SF1. For higher purity needs (like WFI loops), we provide Electropolished finishes of Ra < 0.38μm (15μin) / SF4, which enhances corrosion resistance and cleanability.
Are the manifolds tested for leaks before shipment?
Absolutely. Every Hygienic Manifold undergoes a hydrostatic pressure test (typically at 1.5x working pressure) and a visual borescope inspection to check for weld penetration and surface defects. We provide a full quality dossier including the Hydro Test Report and Surface Roughness Certificate with every shipment.