The pharmaceutical and valve industry – a marriage for life

Everything communicates with everything else – in the pharmaceutical industry, this type of production process has long been more than just a vision for the future. Already, artificial intelligence and the digital transformation are streamlining the first pharmaceutical plants. Good news for an industry which in many countries is one of the important pillars of their economy.

The pharmaceutical industry is accelerating the digital transformation of its laboratories in order to make them more efficient and sustainable. “Large pharmaceutical companies are planning to nearly double their investments in laboratory transformation by 2025 – from 4 percent today to as much as 7 percent of their turnover,” the Capgemini Research Institute (CRI) reports. Almost 75 percent of drug companies have already started modernising their laboratories.

“Cost pressure and international competition are increasing,” explains the Baelz company, a provider of valves, actuators and sensors and more. In order to remain competitive in a challenging environment, the focus is therefore increasingly on digitisation. “It is indispensable both for the use of valves and the management of our plant park,” reports Baelz. Everything communicates with everything else.

Automation and digitisation as a key 
Automation and digitisation are progressing – a development also observed by Baelz. For example, a pharmaceutical company invested around 275 million Euros into a highly automated model factory for the treatment of cancer and cardiovascular conditions. “Thanks to its modular design, you can quickly expand or convert production,” says Baelz.

A Baelz pure steam generator station was designed specifically in order to provide live steam for the production of drugs in their new production building. “Sophisticated control and safety functions as well as integrated automatic desalination and sludge removal ensure a smooth and economical operation,” explains Baelz.

Optimising energy needs 
Increased energy prices are proving a challenge for the pharmaceutical industry. The sector is therefore taking action and installing new plant or optimising existing systems with regard to their energy requirements. Against this background, Bürkert has developed products that are not just more energy-efficient to manufacture, but also reduce energy consumption in subsequent use. Therefore, Bürkert is continuously investing into the development of components. In addition, the company is also trying to think of system solutions that offer increased added value to their customers. An example of this is their FLOWave flow sensor: “The use of an innovative physical sensor principle has enabled us to launch a hygienic, material-saving and very accurate flow sensor.”

Sterile, aseptic and hygienic processes 
A variety of pharmaceutical processes require safety valves in a variety of materials and sizes. “Especially in the core processes for the end product, there is a need for special valves that offer easy process integration with the option of cleaning (CIP) or sterilisation (SIP),” explains the valve manufacturer LESER. “Safety valves for these applications must avoid external contamination.”

With their Clean Service series, LESER has developed safety valves “that meet all the requirements of the pharmaceutical industry”. Its small dead space and gap-free interior construction allow for “a high degree of cleanliness”. During the cleaning process, valves can be opened automatically using the existing pneumatic lift.

For use in sterile, aseptic and hygienic processes, valves must meet high requirements. Since product and process safety is a top priority in these applications, the GEA industry group has equipped its aseptic valves with a hermetic sealing element to prevent microorganisms entering a sterile process. Numerous valve types are required. The spectrum ranges from shut-off, double-seat and tank valves to an extensive portfolio of special valves.

Fast, safe and cost-effective
Faced with a strong and changing pharmaceutical industry, valves are in great demand. SISTO Armaturen S.A. for example, which is part of the KSB Group, has developed an automated media panel solution for the production of immunosuppressants for a French pharmaceutical company. In order to eliminate the risks associated with manual handling, SISTO developed the media panel as a compact, flow-optimised multi-way block diaphragm valve. Equipped with pneumatic drives and electronic feedback units, it automates and streamlines production processes. “This allows them not just to be run faster and more safely, but also more cost-efficiently,” emphasises SISTO.

Investments into modern pharmaceutical plant  
The willingness of the pharmaceutical sector to adapt to industry growth involving increasing requirements by means of investments is great. There are numerous projects to demonstrate this. With an investment volume of almost 300 million Euros, Pfizer has expanded its existing plant into one of the world's most modern production facilities for the pharmaceutical industry in accordance with Industry 4.0 standards. In their “HighCon” factory, drugs for the treatment of diseases such as cancer, cardiovascular conditions and Covid-19 are efficiently manufactured for the global market.

The HighCon system facilitates a highly automated and at the same time sustainable production process. Pfizer: “All machines and processes are intelligently networked using information and communication technologies, enabling the Freiburg Pfizer plant to produce in a faster, more flexible and resource-efficient way.”

Strengthening supply security
In Frankfurt, Sanofi is building a state-of-the-art insulin production facility around 36,000 square meters in size. “The aim is to secure the long-term supply of vital insulin and to strengthen the European security of supply,” explains the company. The investment amounts to about 1.3 billion Euros by 2029. This system will also be largely automated and is designed to meet the highest sustainability standards.

Merck is also investing sustainably. The company is expanding its ADC production capacity in St. Louis, USA, by investing 70 million Euros. Capacities for the production of ADCs (antibody-drug conjugates) for cancer patients will be tripled, and laboratories modernised. Such investments by the pharmaceutical industry are also investments into people’s recovery. The valve industry is part of a marriage for life, sometimes also helping to save lives in their role as a supplier.

Trends and highlights from the valves industry can be experienced at VALVE WORLD EXPO from 1 to 3 December 2026 in Düsseldorf. Current industry and product information can be found on the internet portal at www.valveworldexpo.com.