What is Orbital Welding?

TSA's Orbital Welding

If you are looking for a high-purity solution for your pharma process needs, you have just landed on the right blog! 

In this post, we will discuss exactly what orbital welding is and the advantages of using an Orbitally Welded System. Without further ado, let’s dive directly into the discussion:

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What is Orbital Welding?

As the name suggests, Orbital welding is a special welding technique in which the welding electrode or torch is rotated mechanically around a fixed object, typically a pipe or a tube. It uses Tungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW) methods, which have excellent control and produce clean, high-purity welds. 

Orbital Welding is useful where manual welding is challenging, such as in tight spaces and thin-walled tubes. The process of Orbital Welding ensures welds are high-quality with minimum defects, thereby making it ideal for pharma where sterility is critical. 


What are the advantages of Using Orbitally Welded Systems?

Orbital welding is preferred over other types of welding, such as Manual Tungsten Inert Gas (TIG) welding, Metal Inert Gas Welding (MIG), and Plasma Arc Welding (PAW), in the Pharma Industry for the following reasons: 

1. High Purity and Hygiene

Orbitally Welded systems ensure sterility well maintained for product formulation, cleaning, and injection. For example, the piping systems carrying WFI must be free from particulates, microbes and other contaminants. Since Orbital welding results in clean welds, it reduces the risk of contamination. Thus ensuring the purity by eliminating crevices, cracks or inclusions where microbes could thrive. 

2. Consistent and Automated Welding

Since the orbital welding process is fully automated and can be controlled by pre-set parameters, you can eliminate human error by up to 100%. Process automation ensures consistency in pharmaceutical production, a much-desired quality to thrive successfully in the market in the long run. 

3. Eliminates the Need for Filler Material

Usually, the orbital welding process makes use of the Tungsten Inert Gas (TIG) Method without any filler material. This helps maintain the integrity of the stainless steel or any other high-purity materials used to construct WFI systems. 

4. Compliance with Regulatory Standards

Every system, process, and material used in the pharma industry is obliged to comply with the regulatory standards set by regulatory authorities like FDA, GMP,  and ASME BPE, which mandate hygienic design and cleanability. By using Orbitally Welded systems, the worry of compliance is off the list as it allows detailed documentation and traceability, assisting in the validation process. 

5. Reduced Downtime delays 

Owing to the precision and the repeatability of the orbital welding process, the downtime delays are minimized as there is a low need for rework or repair. As the welds are smooth, clean, and easy to inspect and validate, the time required for conducting routine inspections is minimal, thereby increasing productivity. 

6. Safety and Durability 

By choosing an orbitally welded water purification system, you can be assured of minimal risk of leaks or failures, a critical factor in decision-making when operated at high temperature and pressure.

Since orbital welding produces smooth welds, avoiding any crevices, you also reduce the chances of corrosion damage to the system. As the equipment will be exposed to a variety of chemicals and solutions, it is of utmost importance to invest in the corrosion-proof system. 

TSA’s Orbitally Welded WFI

At TSA, we ensure you receive process equipment and solutions of premium quality. The water produced by our WFI surpasses the most stringent standards globally. 

As we understand the significance of contamination-free systems in the pharma industry, we manufacture state-of-the-art technology to suit your advanced sterile processes. Our Multi-column Distillation Plant is a uniquely efficient purification system with flow rates ranging from 80 LPH to 5000 LPH. It has a sleek mechanical construction in SS 316L with electropolished contact parts. The joints are orbitally welded with a video borescope to ensure compliance with USFDA 21 CFR part 11 and GAMP 5. 

Choose our pre-passivated system that offers high flexibility with a variable production capacity of up to 80% without additional plant modification.

Conclusion

We understand that balancing your budget may be challenging while considering investing in an orbitally welded WFI system. TSA has been a trustworthy partner in the industry for the past 20 years. Delivering our expert advice and solutions around the clock in over 600 countries, we are here to serve more! 


Do not worry, as we are here to support you. Contact us at TSA, and we can craft a budget-friendly solution with zero compromise on quality for you.

FAQ’s

1. How much does an orbitally welded WFI system cost?

The cost of an orbitally welded WFI system depends on its size, the materials used, and the complexity of installation. Usually, these systems are costly because of the high-quality material, such as 316L stainless steel, and the requirement for specialized welding equipment and skilled labor.

2. How is orbital welding inspected and validated in WFI systems?

Non-destructive methods like X-rays or ultrasonic testing are used to inspect and validate orbital welding in WFI systems. In addition to these complex tests, simple tests like visual inspection can be done to detect cracks or corrosion in the weld.

3. What are the challenges of using orbitally welded WFI systems?

In addition to the high initial cost of installing the orbitally welded system, the routine maintenance and inspection could be challenging as it may result in operational downtime and could disrupt the production schedule.

4. How does orbital welding reduce contamination in WFI systems?

By Orbitally Welding the pipes to the system, one can ensure minimum contamination as the welds are smooth, eliminating any crevices, cracks or inclusions where particulates could accumulate or microbes could grow. The precision of the automated welding process ensures the joints are consistent, ensuring the product quality is consistent and contamination-free.

5) What materials are used for piping in WFI systems?

Most commonly, high-purity stainless steel, precisely 316L Stainless steel material, is chosen because of its high durability and resistance to corrosion due to chemicals. Also, this material is highly compatible with extreme conditions during the sterilization processes, such as high temperature and pressure.

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Hetal Panchal is the Vice President in Operations department of TSA Process Equipments (A Thermax Group Company) since 1 s t October 2012.

Holding a qualification in Production Engineering and 28 years of industry experience, he specializes in designing advanced equipment for the pharmaceutical sector. His expertise lies in optimizing production lines, improving efficiency, and ensuring compliance with regulatory standards.
Focused on innovation, he has developed systems that enhances productivity, minimizes downtime, and maintains product quality. Staying current with technological trends, they contribute to ongoing improvements in the industry.
His extensive experience has helped identify opportunities for innovation, streamlining operations and reducing costs. Through his specialized knowledge, more efficient manufacturing processes and higher-quality outputs in pharmaceutical production are delivered.

B.C. Mahesh is the Chairperson of TSA Process Equipment Pvt. Ltd. since Feb 2024.

B.C. Mahesh became a member of the Executive Council in August 2013. He is responsible for the Industrial Product Business (IPB), which consists of Process Heating, Absorption Cooling & Heating Solutions, Water and Waste Solutions, Air Pollution Control, Steam Engineering, Channel Business Group, International Business Group, and Enterprise Sales businesses.
As part of IPB, he also oversees the following wholly-owned subsidiaries
of Thermax – Danstoker, PT Thermax International Indonesia and Rifox.Mahesh joined Thermax as a graduate trainee in 1988 and handled the Materials function for various businesses, including global sourcing, till 1996.
He moved to the Power division(P&ES) and grew to the position of Sales Head and subsequently Head of Projects. He took over as the Head of the SBU for Medium Power Plants in 2009 and finally as Head of Power business in 2012.
Mahesh has worked with Thermax for over 30 years in many functions such as manufacturing, supply chain, sales and marketing, and project management, and has played a significant role in the strategy, expansion and diversification of the Power business.Mahesh completed his Mechanical Engineering from the Visvesvaraya Regional College of Engineering, Nagpur in 1988.

Vishal Mehra is the Director of TSA Process Equipment Pvt. Ltd. since Feb 2024.

Mr. Vishal Mehra is currently serving as the Strategic Business Unit Head for Water & Waste Solutions (WWS) at Thermax Limited. Additionally, he holds a directorial position at TSA Process Equipment, which is known for its expertise in ultra-pure and high-purity water technologies and was recently acquired by Thermax.With over 22 years of experience in the industry, Mr. Mehra’s professional focus includes water management solutions, advanced technology development, and business strategy.
His areas of interest encompass cutting-edge technology, growth strategies, organizational effectiveness, and development.
Mr. Mehra is well qualified in business management and strategy transformation, having completed the Senior Executive Program in Business Management and Strategy Transformation from London Business School. This advanced education supports his extensive experience and expertise in the field.

Sandeep Deshpande has been the Director of TSA Process Equipments Pvt. Ltd. since February 2024.

Currently, he serves as the Head of Corporate Finance and the Industrial Product Group at Thermax Limited. With over 21 years of experience in finance, he has developed expertise in financial consolidation, planning, reporting, costing, accounting, controlling and financial modeling.
Currently, he serves as the Head of Corporate Finance and the Industrial Product Group at Thermax Limited. With over 21 years of experience in finance, he has developed expertise in financial consolidation, planning, reporting, costing, accounting, controlling and financial modeling.
Sandeep is a qualified Cost Accountant Company Secretary, and holds a diploma in IFRS and an advanced diploma in financial management from XLRI. He has extensive experience in financial operations, including financial planning, MIS, budgeting, controlling, audits, and cash flow management. His expertise also spans financial reporting, consolidation, mergers and acquisitions, due diligence, business restructuring, and implementing Internal Financial Control (IFC) and Enterprise Risk Management (ERM). Additionally, Sandeep has hands-on experience with Oracle systems, automation, digitization, and business analytics. He is passionate about driving good governance, improving financial reporting, and leveraging automation and digitization to enhance business analytics.

Rajiv Parikh is the COO of TSA Process Equipments (A Thermax Group Company) since April 2024.

Rajiv is a highly accomplished professional with extensive experience in the pharmaceutical and FMCG sectors, specializing in high-purity and process vessels. He played a key role in establishing TSA Process Equipments Pvt. Ltd., driving its growth and success. His deep technical expertise, combined with a strong understanding of client needs, has enabled him to deliver innovative solutions to complex industry challenges.

Throughout his career, Rajiv has excelled in leadership and sales, consistently launching cutting-edge products that have positively impacted the market. His ability to build lasting client relationships and offer tailored solutions has earned him a reputation as a trusted industry leader.

With a background in Mechanical Engineering, Rajiv blends technical proficiency with strategic vision. His contributions have shaped industry standards and positioned him as a key influencer in the pharmaceutical and FMCG sectors.

Apurva Shah is the CEO of TSA Process Equipments (A Thermax Group Company) since April 2024.

With a career spanning over 24 years, Apurva is the visionary CEO of TSA Process Equipments, where he has led the company to new heights in the High Purity & process equipment industry. A graduate in Mechanical Engineering from Mumbai University, followed by an MBA in Business Management from NMIMS, He brings a strong technical foundation combined with a sharp strategic mindset.

His expertise lies in formulating and executing strategies that drive growth and operational efficiency. Over the years, he has cultivated a deep understanding of market dynamics, positioning TSA Process Equipments for continued success in a competitive landscape.

Outside of his professional pursuits. He is an avid reader, with a particular interest in fiction novels, which fuel his creativity and broaden his perspective.