{"id":4038,"date":"2015-03-26T18:39:36","date_gmt":"2015-03-26T18:39:36","guid":{"rendered":"http:\/\/mirror.s-vt.net\/ve-wasseranlagen-ringleitungen\/"},"modified":"2026-10-26T10:30:17","modified_gmt":"2026-10-26T09:30:17","slug":"di-water-plants","status":"publish","type":"page","link":"https:\/\/www.s-vt.net\/en\/di-water-plants\/","title":{"rendered":"DI Water Plants &#038; Loop Systems"},"content":{"rendered":"<section class='page-content' style=''  ><section class='container'><div class='row' style=''><div class='col-md-12 ' style=''><div class='cma-wysiwyg-editor'><p class=\"svt-lead2\">Water is an important raw material and auxiliary in the manufacture of cosmetic and pharmaceutical products. It also serves as a rinsing agent for the <a href=\"\/cip-sip-systems\/?lang=en\">CIP cleaning<\/a> of plant components and pipes \u2013 which is why DI water plants are among the key systems in production.<\/p><div class=\"svt-ptiles\"><div class=\"svt-ptile\"><i class=\"fa fa-tint\" aria-hidden=\"true\"><\/i><strong>Reverse osmosis &amp; EDI<\/strong><span>Desalination with high rejection rates and a safety margin to the limit values.<\/span><\/div><div class=\"svt-ptile\"><i class=\"fa fa-refresh\" aria-hidden=\"true\"><\/i><strong>Loop systems<\/strong><span>Constant circulation without stagnant water up to every point of use.<\/span><\/div><div class=\"svt-ptile\"><i class=\"fa fa-check-square-o\" aria-hidden=\"true\"><\/i><strong>GMP qualification<\/strong><span>From risk analysis through DQ, IQ, OQ and PQ to the final report.<\/span><\/div><\/div><h2>Water qualities at a glance<\/h2><p>The individual industries place different demands on water quality. Common designations are:<\/p><ul class=\"svt-checks\"><li>DI water \u2013 fully demineralised or deionised water<\/li><li>PW \u2013 Purified Water<\/li><li>HPW \u2013 Highly Purified Water<\/li><li>WFI \u2013 Water for Injection<\/li><\/ul><p>The electrical conductivity in \u00b5S\/cm usually serves as the measure of purity for demineralised water. Conductivity meters record it directly in the plant.<\/p><h2>How water treatment by reverse osmosis works<\/h2><p><a href=\"https:\/\/en.wikipedia.org\/wiki\/Reverse_osmosis\" target=\"_blank\" rel=\"noopener\">Reverse osmosis<\/a> largely removes the dissolved substances from the raw water. A typical treatment chain looks like this:<\/p><ol class=\"svt-steps\"><li><span class=\"svt-step-n\">1<\/span><strong>Filtration<\/strong><span class=\"svt-step-tx\">Multi-layer, cartridge, ultra- or microfilters remove particles and turbidity.<\/span><\/li><li><span class=\"svt-step-n\">2<\/span><strong>Activated carbon<\/strong><span class=\"svt-step-tx\">Activated carbon filters reduce oxidising agents and bind low-molecular organic contaminants.<\/span><\/li><li><span class=\"svt-step-n\">3<\/span><strong>Softening<\/strong><span class=\"svt-step-tx\">Calcium, magnesium and divalent iron are exchanged for sodium ions \u2013 particularly important with hard raw water.<\/span><\/li><li><span class=\"svt-step-n\">4<\/span><strong>Reverse osmosis<\/strong><span class=\"svt-step-tx\">The membrane separates the feed water into permeate (pure water) and concentrate.<\/span><\/li><li><span class=\"svt-step-n\">5<\/span><strong>EDI or 2nd stage<\/strong><span class=\"svt-step-tx\">Electrodeionisation or a second osmosis stage further reduces the residual salt content.<\/span><\/li><li><span class=\"svt-step-n\">6<\/span><strong>Buffer tank<\/strong><span class=\"svt-step-tx\">The DI water is stored and distributed via the loop.<\/span><\/li><\/ol><p>Because of the large internal surface of the resin bed, softening is the most critical element of the entire treatment chain in microbiological terms. Chemical disinfection during regeneration keeps germ counts at a tolerable level. However, hot-water sanitisable plants are increasingly being used.<\/p><p>In modern plants, reverse osmosis is the method of choice for desalination, as it offers numerous advantages over ion exchangers. As a membrane process, it is both a mechanical and a chemical filtration. The plant presses the feed water through a semi-permeable membrane at a pressure above the osmotic pressure.<\/p><p>This creates two streams: a concentrate containing the separated salts and impurities, and a permeate \u2013 pure water with a very low salt content. Reverse osmosis achieves excellent rejection rates for salts, particles, microorganisms and pyrogens. However, the membranes are sensitive to fouling, scaling and oxidising agents.<\/p><p>To reach the required conductivity, either a second stage or an electrodeionisation unit (EDI) follows. Both deliver lower residual salt contents and therefore a greater safety margin to the limit values.<\/p><h2>Control and buffer tank<\/h2><p>With single softening units, the <a href=\"\/control-systems\/?lang=en\">control system<\/a> should schedule regeneration at night. Thanks to pre-treatment, the yield of the reverse osmosis plant rises considerably \u2013 from approx. 50 % to approx. 75 %. The concentrated waste water flows into the drain, while the DI water flows into a buffer tank.<\/p><p>Sensors monitor the level of the buffer tank and act directly on the control system. If the level falls below the minimum, the reverse osmosis plant starts producing water. At maximum level, it stops again. In this way, the plant is optimally utilised.<\/p><h2>Loop systems to the points of use<\/h2><p>Loops run from the storage tank to the individual points of use. They prevent microbial growth caused by stagnant water. The loop passes all points of use, and manual or automatic valves direct the water to the consumers.<\/p><div class=\"svt-kgrid svt-kgrid-2\"><div class=\"svt-kcard\"><i class=\"fa fa-cog\" aria-hidden=\"true\"><\/i><h3>Materials<\/h3><ul class=\"svt-klist\"><li>PVDF \u2013 chemical sanitisation only<\/li><li>stainless steel 1.4404 \/ 1.4435 (316L) \u2013 suitable for sterilisation<\/li><\/ul><\/div><div class=\"svt-kcard\"><i class=\"fa fa-adjust\" aria-hidden=\"true\"><\/i><h3>Surfaces<\/h3><ul class=\"svt-klist\"><li>water-contact surfaces: Ra &lt; 0.8 \u00b5m<\/li><li>WFI lines: Ra 0.6\u20130.4 \u00b5m, electropolished \u2013 depending on customer requirements<\/li><\/ul><\/div><\/div><p>The following principles also apply to a hygienic loop system:<\/p><ul class=\"svt-checks\"><li>connect all components compactly with minimal dead space and ensure all areas are flushed<\/li><li>no connections with seal offset or threads in the loops<\/li><li>preferably aseptic connections to DIN 11864; where hot-cold changes occur, sterile flange connections if possible<\/li><li>low-dead-space T-diaphragm valves at the points of use<\/li><li>sealing materials with FDA approval (Food and Drug Administration)<\/li><li>passivation after completion of the loops and plant components<\/li><\/ul><h2>Disinfection, sanitisation and sterilisation<\/h2><p>To keep the water free of germs, operators combine different methods. Sanitisation and SIP processes run in defined cycles. The plant must be designed for the respective method.<\/p><div class=\"svt-kgrid svt-kgrid-2\"><div class=\"svt-kcard\"><i class=\"fa fa-sun-o\" aria-hidden=\"true\"><\/i><h3>UV disinfection<\/h3><p>Ultraviolet light with a wavelength of 254 nm destroys the DNA, cell membrane and enzymes of microorganisms. The pre-treated water flows through an irradiation chamber in a controlled manner. Turbulent flow improves the effect.<\/p><\/div><div class=\"svt-kcard\"><i class=\"fa fa-fire\" aria-hidden=\"true\"><\/i><h3>Sanitisation at 80 \u00b0C<\/h3><p>A DI water plant should be sanitised at least four times a year. A heat exchanger heats the tank and pipe network to 80 \u00b0C. The hot water then circulates for one hour. Afterwards, the system is drained and refilled with cold water \u2013 fully automatically if required.<\/p><\/div><div class=\"svt-kcard\"><i class=\"fa fa-tachometer\" aria-hidden=\"true\"><\/i><h3>Pressurised hot water sterilisation 110\u2013130 \u00b0C<\/h3><p>The sequence is similar to sanitisation, but at higher temperatures. Above 100 \u00b0C, a steam overpressure builds up in addition to the pump pressure: about 0.5 bar at 110 \u00b0C and around 1 bar at 121 \u00b0C (approx. 2 bar absolute). The plant must therefore be designed accordingly.<\/p><p>From 100 \u00b0C, the steam displaces the air in the tank. The vent valve on the sterile filter then closes so that pressure and temperature build up and are maintained. This sequence can also run fully automatically.<\/p><\/div><div class=\"svt-kcard\"><i class=\"fa fa-cloud\" aria-hidden=\"true\"><\/i><h3>Sterilisation with pure steam<\/h3><p>This method requires a higher investment, because the plant components must meet higher requirements, e.g. the AD 2000 code or EN ISO 17665. In addition, comprehensive qualification and validation are needed. You will find details of the process in the next section.<\/p><\/div><\/div><h2>Pure steam sterilisation process<\/h2><p>For pure steam sterilisation, all plant components must be completely drained. Steam traps with suitable check valves are required at the points of use and at the lowest points of the pipes. The condensate must drain safely, and nobody must be able to get injured on the hot lines.<\/p><p>For reliable venting, it is advisable to put the storage tank and pipe network under vacuum. Pure steam then flows in, and the temperature is controlled via the pressure. It is important that the pipes are also connected to the steam network. Only then does the steam flow all the way to the condensate drain points.<\/p><p>Temperature sensors at hard-to-sterilise points and at the condensate drains record the values and adjust the steam supply. As soon as all sensors reach the defined sterilisation temperature (e.g. 121 \u00b0C or higher), the sterilisation time begins. The prerequisites for this are:<\/p><ul class=\"svt-checks\"><li>reproducibly controllable sterilisation processes<\/li><li>stored and documented quality-relevant measured values<\/li><li>a fully automatic sterilisation sequence<\/li><li>SOPs for handling the individual sterilisation methods<\/li><\/ul><h2>Heating of water circuits<\/h2><p>Leak-proof shell-and-tube heat exchangers heat the water circuit. To prevent microbial growth, hot water should be stored at 70\u201399 \u00b0C. Cold water, on the other hand, should stay below 18 \u00b0C. A recooler in the loop takes care of this.<\/p><h2>Qualification of DI water plants<\/h2><p>Qualification is required to meet the GMP requirements for water plants. It comprises the following steps:<\/p><ul class=\"svt-tags\"><li>RA \u2013 Risk analysis<\/li><li><a href=\"\/design-qualification\/?lang=en\">DQ \u2013 Design qualification<\/a><\/li><li>IQ \u2013 Installation qualification<\/li><li>CAL \u2013 Calibration<\/li><li>OQ \u2013 Operational qualification<\/li><li>PQ \u2013 Performance qualification<\/li><li>R \u2013 Report<\/li><\/ul><p>The qualification work should already be clearly specified in the requirement specification.<\/p><p><strong>SEEFRIED Verfahrenstechnik GmbH<\/strong> supports you both in the design and in the qualification of your DI water plant.<\/p><h2>Frequently Asked Questions about DI water plants and loop systems<\/h2>\n<h3>Which water qualities are used in pharma and cosmetics?<\/h3>\n<p>Common qualities are DI water (demineralised or deionised water), Purified Water (PW), Highly Purified Water (HPW) and Water for Injection (WFI). Purity is usually determined via electrical conductivity in \u00b5S\/cm.<\/p>\n<h3>How is DI water produced by reverse osmosis?<\/h3>\n<p>After a filtration stage and, if required, activated carbon filtration and softening, reverse osmosis forces the water through a semi-permeable membrane. For very low conductivities, a second stage or electrodeionisation (EDI) follows. The purified water is stored in a buffer tank.<\/p>\n<h3>Why are loop (circular) pipelines used?<\/h3>\n<p>Loop pipelines keep the water constantly moving and prevent microbial growth caused by standing water. Typical materials are stainless steel 316L or PVDF with surfaces Ra &lt; 0.8 \u00b5m, low-dead-leg diaphragm valves and sterile connections according to DIN 11864.<\/p>\n<h3>How often should a DI water plant be sanitised?<\/h3>\n<p>At least four times a year, usually by heating to 80 \u00b0C and circulating for one hour. Alternatives are pressurised hot water sterilisation at 110\u2013130 \u00b0C or sterilisation with pure steam.<\/p>\n<h3>Which qualification do GMP water plants require?<\/h3>\n<p>Risk analysis, DQ, IQ, calibration, OQ, PQ and a final report. The qualification work should already be specified in the requirement specification.<\/p>\n<p><h2 class=\"svt-pcta-h\">Talk to us<\/h2><div class=\"svt-pcta svt-pcta-m\"><div class=\"svt-pcta-tx\">We are happy to advise you on DI water plants and loop systems \u2013 by phone at <a href=\"tel:+494203789492\">+49 4203 789492<\/a> or by e-mail at <a href=\"mailto:&#105;n&#102;&#111;&#64;&#115;&#45;&#118;t.&#110;et\">info&#64;&#115;-&#118;&#116;&#46;ne&#116;<\/a>.<\/div><div class=\"svt-pcta-btns\"><a class=\"svt-btn svt-btn-primary\" href=\"\/contact\/?lang=en&amp;produkt=Verfahrenstechnische%20Beratung\">Request a consultation<\/a><a class=\"svt-btn svt-btn-ghost\" href=\"\/process-technology\/?lang=en\">All consulting services<\/a><\/div><\/div><h2>More consulting services<\/h2><div class=\"svt-sgrid\"><a class=\"svt-scard\" href=\"\/homogenisation-technology\/?lang=en\"><span>Homogenisation technology<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/process-engineering\/?lang=en\"><span>Agitation and homogenisation technology<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/temperature-control-systems\/?lang=en\"><span>Temperature control systems<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/cip-sip-systems\/?lang=en\"><span>CIP\/SIP systems<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/transfer-systems\/?lang=en\"><span>Transfer systems<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/control-systems\/?lang=en\"><span>Control systems<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/software-interface-description\/?lang=en\"><span>Software &amp; interface descriptions<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/steam-plants\/?lang=en\"><span>Steam systems<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/storage-tanks-containers\/?lang=en\"><span>Storage tanks &amp; containers<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><a class=\"svt-scard\" href=\"\/pipelines\/?lang=en\"><span>Pipelines<\/span><i class=\"fa fa-angle-right\" aria-hidden=\"true\"><\/i><\/a><\/div><script type=\"application\/ld+json\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Service\",\"name\":\"Design and qualification of DI water plants and loop systems\",\"description\":\"Planning and design of water treatment plants (reverse osmosis, EDI), loop pipelines, sanitisation and sterilisation as well as GMP qualification for pharma and cosmetics.\",\"url\":\"https:\/\/www.s-vt.net\/di-water-plants\/?lang=en\",\"provider\":{\"@type\":\"Organization\",\"@id\":\"https:\/\/www.s-vt.net\/#seefried\",\"name\":\"SEEFRIED Verfahrenstechnik GmbH\",\"url\":\"https:\/\/www.s-vt.net\/\",\"telephone\":\"+49 4203 789492\"},\"areaServed\":\"Worldwide\"},{\"@type\":\"FAQPage\",\"mainEntity\":[{\"@type\":\"Question\",\"name\":\"Which water qualities are used in pharma and cosmetics?\",\"acceptedAnswer\":{\"@type\":\"Answer\",\"text\":\"Common qualities are DI water (demineralised or deionised water), Purified Water (PW), Highly Purified Water (HPW) and Water for Injection (WFI). 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