Franz Ziel GmbH - No compromises in terms of tightness

For more than 40 years, the German Franz Ziel GmbH has been offering its customers in the pharmaceutical sector tailor-made solutions and, in the course of this, has developed into a leading provider in the field of GMP compliance services. One product area of the company with 230 employees specializes in services relating to cleanroom technology for safe production environments. In this field, Franz Ziel develops and manufactures systems that are subsequently implemented at customers located in the pharmaceutical industry worldwide. Starting with the individual planning through the design to the final commissioning and acceptance as well as the subsequent support the company offers comprehensive services from a single source. This includes cleanroom systems such as isolators, which offer the highest possible level of safety. Markus Hörsch, Division Manager for Sales and Marketing at Franz Ziel, explains: “With our solutions, we pay particular attention to ensuring that the employees, the products and the production environment are protected in the best possible way in the processes. Our principle “PROTECTING LIFE WITH TECHNOLOGY” hits the nail on the head and describes the basis of our entrepreneurial activities. To ensure that we always comply with this and achieve optimum results, the quality of the individual components installed in our systems plays a decisive role.” Against this background, all components are intensively tested before they are used here. For almost 20 years, Franz Ziel GmbH has relied on the Swiss company RICO Sicherheitstechnik AG as a supplier in terms of safety. RICO provides the gas-tight butterfly valves for the systems manufactured here and always meets the high-quality requirements due to continuous further development

In cleanroom technology, and especially in isolator technology, the sealing off of certain areas is indispensable. In some cases, hazardous substances must not be allowed to leave the work area, and in other cases, germs and bacteria must not be allowed to enter from the outside so that the product is not contaminated. The company’s portfolio therefore includes Restricted Access Barrier Systems (RABS) and isolators in various designs. These containment solutions for aseptic processes are chosen for instance in filling and loading/unloading freeze dryers or other critical processes. The isolators are used for aseptic filling of pharmaceuticals, which, in contrast to filling in clean rooms, prevent direct manipulation by humans and thus serve to protect the product as well as people. The isolator housing with its integrated glove ports creates a barrier between the operator and the product. The ventilation system installed inside the equipment with its controlled pressure regulation further increases the safety for product or operator. The plants are equipped with supply and exhaust air systems, using HEPA filters to purify the air flow. “Before the process starts, bio-decontamination with evaporated H₂O₂ is carried out. In the course of this, it is essential that the gas does not get into the ambient air and that absolute gas tightness is guaranteed,” says Markus Hörsch. Gas-tight butterfly valves from RICO Sicherheitstechnik AG are therefore integrated into the technical area of the systems on both, the supply air and exhaust air sides. The RAPIDO butterfly valves are able to control the flow of air in the ventilation duct and to close the duct 100% gas-tight. Actuators are used to regulate the valves. “The RAPIDO system ensures continuous air exchange during normal operation of our systems thanks to the variable valve position. At the same time, the pressures inside the isolator are regulated,” explains Markus Hörsch, adding that the flap position monitoring and safety function in the event of a fault were also decisive for the purchase. Because an important criterion was that the tightness of the butterfly valves can be checked in the installed state – this can be done quickly and easily by means of a hand pump and pressure gauge via the so-called PERFEKT system of the RICO butterfly valves.

With regard to the handling of RICO products, Markus Hörsch is also very satisfied and explains that the valves have a very good quality of workmanship and a slim, yet robust design. Another advantage is that they can be installed by the Franz Ziel employees on their own. Regular checking of the valve function is a matter of course as part of the processes. As the systems must be subjected to a pressure test before each decontamination cycle, it would be noticed immediately if something was leaking and thus the process could not start. ” We are very satisfied with the partnership with RICO. We focus on the quality of our technologies and systems. RICO follows the same values, which is fully reflected in the products supplied.” says Markus Hörsch, assessing the cooperation and adds that Franz Ziel will continue to rely on the high-quality valves from the Swiss experts in the future.

Although the previous valves were still functional due to preventive maintenance, the Institute decided to replace them before possible failures in order to be on the safe side and to be at the cutting edge of technology. Thanks to the positive experience, RICO’s solutions have been relied on here as well. “One of the main reasons for continuing the cooperation with RICO is the reliability of the product,” emphasises Fluri. RICO knows about the high safety requirements that the valves have to fulfil and for this reason enjoys a high status at the Institute. A decisive point for the implementation of the project was also that the new products were supplied identical in construction to the old ones. The advantage of this is that the valves could thus be replaced quickly and easily, no further structural measures were necessary and the Institute did not have to fear any critical situation. “In a project of this size, it’s a decisive factor for us that there is physical proximity between the Institute and the supplier,” adds Fluri. If difficulties arise during installation or commissioning, RICO’s service technicians are on site immediately and can support the IVI team of technicians. “Our technicians know the systems installed here in depth, so there’s profound know-how – also with regard to the handling of the butterfly valves,” notes Peter Fluri. The regular valve tests and revisions are carried out by the Institute’s own staff, and RICO’s service technicians are always on hand to answer questions. The IVI leaves the necessary repairs of the automatic valves entirely to RICO’s specialists – this is the only way to maintain 100 percent functionality for a long time. According to the technical manager, the cooperation between IVI and RICO proves to be a win-win situation, as all decisive criteria could be fulfilled. “We appreciate RICO as a reliable partner with whose help we can continue to provide safety for our employees and the environment. This will enable us to continue to perform our tasks at the Institute safely for the next 23 years,” Fluri mentions in conclusion.

RICO Sicherheitstechnik AG, based in Herisau, Switzerland, has been developing and selling various components for explosion isolation since 1988. With the help of high-quality products such as explosion isolation valves (VENTEX®) and explosion isolation slide valves, the company secures plants and protects industrial facilities from the spread of explosions. The solutions are mainly used in the pharmaceutical industry, chemical/petrochemical industry, research laboratories, silos, mills, dryers and separators as well as extraction systems. Furthermore, the specialists’ portfolio also includes butterfly valves that can shut off ventilation ducts 100% gas-tight and offer the rare advantage of being able to easily check the tightness when installed. Possible areas of application include the pharmaceutical industry (e.g. insulators), nuclear power plants, military/civil defence, chemicals/petrochemicals, research laboratories and hospitals. Safety always comes first. Reliability, experience, innovation and flexibility are characteristics that distinguish RICO Sicherheitstechnik AG just as much as the consideration of individual wishes or the development of special designs. A team of experts also advises and supports customers in the selection of suitable components. RICO Sicherheitstechnik AG is certified according to ISO 9001:2008 and ATEX Directive 94/9/EC In the field of explosion protection, an ATEX type test is carried out for each component under a wide range of process conditions. The company also carries out various quality tests – some of which are customer-specific – for the gas-tight butterfly valves. These are based on the requirements of the respective application. As a matter of principle, every single product at RICO Sicherheitstechnik AG undergoes final testing. This principle has guaranteed the highest quality for maximum safety requirements for over 25 years.