PG Diploma in Piping Engineering – Topic
Pharmaceutical, Food & Beverage Plants – Simple Explanation for Piping Engineers
In modern industry, two very important plant types are:
- Pharmaceutical Plant – where medicines are produced
- Food & Beverage Plant – where food and drinks are processed
Both plants use many pipes, pumps, tanks and machines. The main job of the piping system is to move different fluids (liquids and gases) safely from one equipment to another. Because these products are consumed by humans, cleanliness and hygiene are very important.
1. Pharmaceutical Plant
A pharmaceutical plant is a factory where tablets, syrups, injections, vaccines and other medicines are produced. The environment is very clean and controlled. Even a small contamination can spoil a full batch of medicine.
1.1 Fluids Used in Pharmaceutical Plants
In pharmaceutical plants, many different chemicals and special grade waters are used. Each one has different nature and properties. Some common fluids are:
- Purified Water (PW) – clean water without minerals and impurities.
- Water for Injection (WFI) – very pure water used for injections and critical products.
- Clean Steam – used for sterilizing equipment and pipelines.
- Active Pharmaceutical Ingredients (API) – main drug chemicals.
- Solvents – such as ethanol, methanol or acetone for reactions and cleaning.
- Process gases – nitrogen, clean compressed air etc.
Each fluid can be corrosive, flammable, sensitive to temperature or easily contaminated. So, the piping design must protect the product and also ensure safety of people and equipment.
1.2 Effect of Temperature and Pressure
In a pharmaceutical plant, temperature and pressure have a huge impact on quality:
- Some reactions happen only at a specific temperature range.
- Too low temperature may allow bacteria to grow in water lines.
- Too high temperature may damage heat-sensitive drugs.
- High pressure is needed to circulate liquids through filters and reactors.
- Incorrect pressure can cause leaks, foaming or unsafe operating conditions.
For example, Water for Injection is often circulated at a temperature above 80°C to prevent bacterial growth. This means the piping must withstand both high temperature and pressure while still remaining very clean inside.
1.3 Piping Material and Construction
Because products must be very pure, the piping system in pharmaceutical plants is designed to be highly hygienic:
- Most pipes are stainless steel 316L.
- Internal surface is highly polished to a very smooth finish to avoid dirt sticking inside.
- Pipes are welded using orbital welding to avoid human contamination and to get smooth joints.
- Piping layout avoids any dead legs or pockets where fluid can stand still.
- Pipes are slightly sloped so that water or steam can drain fully.
For cleaning, systems like CIP (Cleaning in Place) and SIP (Sterilization in Place) are used. Cleaning chemicals and steam are circulated through the same pipes to wash and sterilize them without dismantling.
1.4 Typical Equipment in Pharmaceutical Plants
- Reactors and mixing tanks
- Bioreactors and fermenters
- Heat exchangers
- Filtration units and membrane systems
- Clean steam generators
- CIP / SIP skids
All these are connected by a network of hygienic pipelines, valves and instruments. The piping engineer has to ensure correct routing, support, slope, material and pressure rating.
1.5 Safety and Regulations
Pharmaceutical plants are controlled by strict rules like GMP (Good Manufacturing Practice) and regulations from authorities such as FDA. Engineers must:
- Prevent contamination (chemical, microbial or cross contamination between products).
- Handle flammable or toxic solvents safely.
- Provide proper venting, relief valves and emergency systems.
- Maintain full documentation of design, validation and cleaning procedures.
2. Food & Beverage Plant
Food & Beverage plants produce milk products, juices, soft drinks, bottled water, beer, sauces, oils and many other items that we use in daily life. Like pharmaceutical plants, they also need good hygiene, but the sterility level may be slightly lower depending on the product.
2.1 Fluids in Food & Beverage Plants
Fluids in these plants are mostly food-grade materials. Some are thin like water and some are thick (viscous) like syrup or cream. Common examples:
- Milk and cream
- Juices and fruit pulp
- Carbonated soft drinks
- Beer and wine
- Sugar syrup
- Edible oils
- Drinking water
These fluids can be sticky and may leave deposits. They must be transported in a way that avoids contamination and allows easy cleaning.
2.2 Role of Temperature and Pressure
In food processing, temperature and pressure are also very important:
- Pasteurization – milk or juice is heated to a specific temperature for a fixed time to kill harmful bacteria.
- Cooling – after heating, the product is quickly cooled to keep taste and increase shelf life.
- Freezing or chilling – for ice cream and frozen products.
- Carbonation pressure – soft drinks and beer require a certain pressure to keep CO2 dissolved.
- Filling pressure – proper pressure is needed to fill bottles, cans or packets at high speed without foaming or overflow.
All these requirements are handled through correct design of pumps, pipes, valves and control systems.
2.3 Piping Materials and Hygienic Design
Food & Beverage piping is also hygienic but sometimes slightly less strict than pharmaceutical. Key features:
- Pipes are usually stainless steel 304 or 316.
- Fittings are mostly tri-clamp or other sanitary fittings (no threaded joints in product contact area).
- All bends and tees are smooth and without sharp corners.
- Dead legs are avoided to prevent product stagnation and bacterial growth.
- CIP systems are used to clean pipes with hot water and cleaning chemicals.
2.4 Typical Equipment in Food & Beverage Plants
- Pasteurizers
- Mixing and blending tanks
- Homogenizers
- Evaporators and dryers
- Bottle / can filling machines
- Conveyors and packing machines
- CIP skids for cleaning
The piping network connects raw material storage, processing area and packaging area. Good routing reduces pressure drop, avoids air pockets and keeps cleaning simple.
2.5 Safety and Quality
Food & Beverage plants follow standards like HACCP and food safety regulations of each country. Engineers and operators must:
- Prevent contamination from bacteria, insects, dust or foreign particles.
- Avoid mixing of allergens (for example nuts, gluten, dairy) between product lines.
- Ensure correct temperature control to avoid spoilage.
- Maintain records of cleaning, maintenance and product batches.
3. Comparison – Pharmaceutical vs Food & Beverage Plant
| Point | Pharmaceutical Plant | Food & Beverage Plant |
|---|---|---|
| Product Type | Medicines, vaccines, injections, tablets | Milk, juice, soft drink, beer, edible oils, packed food |
| Required Cleanliness | Very high, often sterile | Very hygienic but not always sterile |
| Typical Pipe Material | Stainless Steel 316L with high polish | Stainless Steel 304/316 |
| Fluids | APIs, solvents, WFI, purified water, clean steam | Milk, water, juices, syrups, beer, oils |
| Main Design Focus | Sterility, no contamination, precise control of reaction | Hygiene, taste, shelf life, fast and safe packaging |
| Cleaning Method | CIP + SIP (Cleaning and Sterilization in Place) | Mostly CIP, hot water and chemicals |
4. Role of Piping Engineer in These Plants
For both pharmaceutical and food & beverage plants, the piping engineer has an important role:
- Select proper pipe material and rating based on fluid, temperature and pressure.
- Prepare piping layout that avoids dead legs and is easy to support and clean.
- Ensure that the system can be drained, cleaned and sterilized properly.
- Coordinate with process, mechanical, electrical and instrumentation teams.
- Prepare drawings, isometrics and support plans.
- Follow relevant codes, standards and regulations.
When these aspects are handled correctly, the plant can run safely, produce good quality products and meet all legal requirements.
5. Summary
Pharmaceutical plants and Food & Beverage plants may look similar because of their stainless-steel pipes and shiny equipment, but their design philosophy is different. Pharma focuses on sterility and drug safety, while food and beverage focus on hygiene, taste and shelf life.
For a piping engineer or a student, understanding the type of fluids, the effect of temperature and pressure and the cleaning requirements in each plant is the first step towards proper design.