Hose Rail Mixing Battery

A hose rail mixing battery is a fixed overhead or wall-mounted SS 316L pipe manifold rail carrying multiple individually valved Tri-Clamp or camlock outlet ports — each port supplies a defined process fluid (hot water, cold water, CIP caustic, CIP acid, steam, nitrogen, or product) to flexible hose connections below, enabling process operators to connect, route, and disconnect individual fluid streams to portable vessels, mobile IBC fill stations, and cleaning connections without using fixed pipework. A typical battery carries 4–24 ports across 1–6 different fluids on a single rail, serving a defined process bay — the standard flexible connection infrastructure in multi-product pharmaceutical, food, and personal care manufacturing suites.

Challenges

Cross-Connection Error (Wrong Fluid Connected to Wrong Vessel)

Operator error connecting acid CIP hose to a vessel that should receive product — cross-contamination or safety incident.

Residual Fluid Draining at Hose Disconnect Creates Spill and Slip Hazard

Hose contains fluid at disconnect — residual spills onto floor at Tri-Clamp release point.

Rail Manifold Pressure Imbalance Across Multiple Simultaneous Connections

Multiple simultaneous outlets on the same fluid header create unequal flow distribution — near outlets receive higher flow.

Valve Seal Degradation in CIP Chemical Service (NaOH / HNO₃)

EPDM or silicone valve seats swell or harden in caustic-acid cycling — valve leaks past closed seat.

CIP Dead Legs at Capped Outlet Ports Between Connections

Unused capped Tri-Clamp ports form dead legs >6× diameter — fluid pools and is not swept during CIP of the main rail.

Solutions

Applications

Models & Capacities

Hose Rail Mixing Battery — Models & Configurations (4-Port Manual to 24-Port PLC-Controlled)

Model

Type

No. of Fluid Headers

No. of Outlet Ports

Outlet Connection

Rail Length [mm]

Rail Tube Ø [mm]

Max Working Pressure [bar]

Max Temp [°C]

Valve Type

Control

Weight [kg]

HRB-04-2F

Wall-mounted

2

4

DN 25 Tri-Clamp

800

Ø38 (DN 32)

6

130

Manual butterfly

Manual

22

HRB-06-3F

Wall-mounted

3

6

DN 25 Tri-Clamp

1,200

Ø38 (DN 32)

6

130

Manual butterfly

Manual

35

HRB-08-3F

Wall-mounted

3

8

DN 25 Tri-Clamp

1,600

Ø38 (DN 32)

6

130

Manual butterfly

Manual

48

HRB-08-4F

Overhead rail

4

8

DN 40 Tri-Clamp

1,600

Ø51 (DN 40)

6

150

Manual butterfly

Manual

65

HRB-12-4F

Overhead rail

4

12

DN 40 Tri-Clamp

2,400

Ø51 (DN 40)

6

150

Manual butterfly

Manual

95

HRB-12-5F-P

Overhead rail

5

12

DN 40 Tri-Clamp

2,400

Ø51 (DN 40)

6

150

Pneumatic butterfly

PLC

160

HRB-16-5F-P

Overhead rail

5

16

DN 40 Tri-Clamp

3,200

Ø51 (DN 40)

6

150

Pneumatic butterfly

PLC

210

HRB-16-6F-P

Overhead rail

6

16

DN 40 Tri-Clamp

3,200

Ø63.5 (DN 50)

10

160

Pneumatic butterfly

PLC

280

HRB-20-6F-P

Overhead rail

6

20

DN 40 Tri-Clamp

4,000

Ø63.5 (DN 50)

10

160

Pneumatic butterfly

PLC

360

HRB-24-6F-P

Overhead rail

6

24

DN 50 Tri-Clamp

4,800

Ø76.1 (DN 65)

10

160

Pneumatic butterfly

PLC

480

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