A valve cluster is a compact, pre-engineered group of automated valves that routes product, CIP, and utilities between tanks, lines, and equipment from a single location. JBM clusters cover mix-proof, divert panel, butterfly, diaphragm block, zero dead-leg, CIP matrix, tank outlet, and jacket utility designs from 1” to 4” OD tube with 2 to 12 valves, built to ASME BPE and EHEDG principles with PLC-integrated control tops.
Valves are mounted on a common frame with short, self-draining interconnecting tube. Double-seat mix-proof valves keep product and CIP separated in adjacent lines with a leakage chamber open to drain. Diaphragm valve blocks machine several ports into one body to remove dead legs. Each valve has a control top with solenoids and position feedback, so the PLC runs route sequences, confirms valve states, and interlocks against unsafe paths.
Challenges
Cross-Contamination
Product and CIP in adjacent lines risk mixing through a single seat.
Dead Legs
Tee branches and closed valves trap product and resist cleaning.
Route Errors
Manual swing bends and wrong valve states send product to the wrong tank.
Space and Access
Scattered valves spread across the plant are slow to maintain.
Air and Wiring Complexity
Many actuators need tidy air and signal distribution.
Solutions
- Double-Seat Mix-Proof Valves: Leakage chamber vents to drain and seat lift cleaning is included.
- Diaphragm Blocks + Zero Dead-Leg Design: Machined multi-port bodies remove branch dead legs.
- Control Tops with Feedback: PLC confirms every valve position before a route runs.
- Grouped Compact Frames: All valves at one serviceable location with drainable slopes.
- AS-i / IO-Link Networking: Single cable for power, signals, and feedback.
Applications
- Pharmaceutical: Media, buffer, and product transfer with CIP / SIP routing.
- Dairy: Milk reception, silo, and pasteurizer routing.
- Beverages: Brewery tank farms, syrup rooms, and CIP distribution.
- Food & Cosmetics: Sauce, cream, and emulsion transfer between vessels.
Types & Configurations
| Type | Code | Design & Operation | Size | Rating | Typical Use |
|---|---|---|---|---|---|
| Routing | |||||
| Mix-Proof / Double-Seat Cluster | MP | Double-seat valves with leakage chamber and seat lift | 1”–4” | Up to 10 bar | Product and CIP separation |
| Divert Panel (Swing Bend / Flow Plate) | DP | Manual ports connected by swing bend with proximity sensors | 1”–4” | Up to 6 bar | Low-cost manual routing |
| Butterfly Valve Cluster (Automated) | BF | Butterfly valves with actuators on a common header | 1”–4” | Up to 6 bar | Utility and low-risk routing |
| CIP Supply / Return Valve Matrix | CIP | Valve matrix selecting CIP circuits and returns | 1.5”–4” | Up to 6 bar | Central CIP distribution |
| Hygienic Pharma | |||||
| Diaphragm Valve Block / Multi-Port Valve | DB | Machined block with multiple diaphragm valves | ½”–2” | Up to 10 bar, SIP | Pharma process routing |
| Zero Dead-Leg Valve Cluster | ZD | Valves welded directly on the main loop | ½”–3” | Up to 10 bar, SIP | WFI and clean utilities |
| Vessel & Utility | |||||
| Tank Outlet Valve Cluster | TO | Bottom outlet valve with routing to several lines | 1”–4” | Up to 6 bar | Tank farms and vessels |
| Jacket Utility Valve Cluster | JU | Steam, CW, and CHW changeover with drain and vent | 1”–3” | Up to 10 bar | Heating and cooling jackets |
| Automation | |||||
| Automated Manifold with Control Tops | -AT | Solenoids, position feedback, AS-i / IO-Link, PLC routing | All sizes | As cluster | Fully automated plants |
Models & Sizes: 1” to 4” OD Tube
| Model | Tube OD [in (mm)] | Valves [nos] | Routes [nos] | Kv per Valve [m³/h] | Frame W×H [mm] | Air per Stroke [NL] | Weight [kg] |
|---|---|---|---|---|---|---|---|
| VC-1-04 | 1″ (25.4) | 4 | 3 | 18 | 700×1,300 | 0.3 | 80 |
| VC-1-08 | 1″ (25.4) | 8 | 6 | 18 | 1,100×1,300 | 0.3 | 120 |
| VC-1.5-04 | 1.5″ (38.1) | 4 | 3 | 40 | 800×1,400 | 0.5 | 100 |
| VC-1.5-08 | 1.5″ (38.1) | 8 | 6 | 40 | 1,300×1,400 | 0.5 | 160 |
| VC-2-06 | 2″ (50.8) | 6 | 4 | 75 | 1,200×1,500 | 0.8 | 160 |
| VC-2-10 | 2″ (50.8) | 10 | 8 | 75 | 1,800×1,500 | 0.8 | 250 |
| VC-2.5-08 | 2.5″ (63.5) | 8 | 6 | 120 | 1,700×1,600 | 1.2 | 270 |
| VC-2.5-12 | 2.5″ (63.5) | 12 | 9 | 120 | 2,400×1,600 | 1.2 | 390 |
| VC-3-08 | 3″ (76.2) | 8 | 6 | 180 | 1,900×1,700 | 1.8 | 350 |
| VC-3-12 | 3″ (76.2) | 12 | 9 | 180 | 2,700×1,700 | 1.8 | 500 |
| VC-4-08 | 4″ (101.6) | 8 | 6 | 320 | 2,300×1,900 | 3.0 | 530 |
| VC-4-12 | 4″ (101.6) | 12 | 9 | 320 | 3,300×1,900 | 3.0 | 770 |