Din 11864-1 Design And Sealing Principle Of Aseptic Male Flexible Tube Connector

To eliminate microbial entrapment in hose connections, specify a din11864 aseptic male coupling with Form A O‑ring sealing. Manufactured from SS316L, available DN10‑DN100. The O‑ring deforms under tightening to fill the gap between parts, leaving no unswept volume. Internal finish Ra ≤ 0.8 µm supports CIP/SIP. This coupling removes crevices where bacteria hide, maintaining sterility across batch changes without cross‑contamination.

The Microbial Risk in Conventional Couplings

Standard threaded or clamped hose couplings contain dead legs—stagnant zones where biofilm forms and persists. These areas resist CIP penetration and steam sterilization. The din 11864 1 eliminates this risk through an O‑ring‑based sealing principle that leaves no dead space.

Contamination sources eliminated:

•  Dead legs in threaded connections

•  Biofilm in un‑swept crevices

•  Residue accumulation around seals

•  CIP fluid trapped in blind volumes

•  Steam condensate pools in low pockets

Zero‑Dead‑Leg Sealing Principle

The coupling has a male part (GS), a liner (BS), an O‑ring, and a union nut. Tightening the nut compresses the O‑ring, creating a seal that fills the gap between parts without unswept volume. The connection has no dead space.

Sealing advantages:

1. Defined O‑ring deformation ensures repeatable seals

2. Zero‑dead‑leg design removes microbial hiding places

3. Seal geometry prevents fluid entrapment

4. No threaded crevices trap residue

5. Compatible with EPDM, silicone, FKM O‑rings

The O‑ring is FDA‑compliant and meets EC 1935‑2004 for food‑contact materials.

Materials and Specifications

The coupling body and nut are SS316L (1.4404). SS316L provides molybdenum for corrosion resistance against saline buffers, acids, and CIP chemicals. Class H3 offers internal surface finish Ra ≤ 0.8 µm—meeting GMP standards.

Form A Configuration and Sizes

The din 11864 1 form a is the standard O‑ring sealing version. Sizes DN10 to DN100, with O‑ring ID and cross‑section matched to each DN. The coupling welds to tubes per DIN 11866. For O‑ring material selection, refer to the table below.

The din 11864 1 form a ensures interchangeability across standard fittings while maintaining zero‑dead‑leg sealing.

din 11864 Series Overview

The standard has three parts:

• din 11864 1: Aseptic screwed unions (threaded)

• din 11864 2: Aseptic flange connections

• din 11864 3: Aseptic clamp connections

The din 11864 1 suits hose connections and frequent disconnection. The din 11864 2 offers stability for larger systems. The din 11864 3 provides rapid assembly for modular systems.

Applications and Selection Considerations

1. The din 11864 1 coupling is installed in fermenters and bioreactors for media transfer and sampling, buffer preparation lines, chromatography skids, CIP supply lines, and purified water/WFI loops.

2. When selecting a coupling, evaluate operating pressure, process temperature range, chemical compatibility of O‑ring material, and expected cycle frequency.

3. For multi‑product facilities, the coupling’s ability to maintain sterility through repeated connections makes it the preferred choice.

4. Standard DN10‑DN100 sizes cover most pharmaceutical hose connection requirements.

Installation and Maintenance

Butt weld to tube ends using orbital welding equipment. Maintain internal finish and avoid heat‑affected zone contamination. Inspect and replace O‑rings every 6–12 months depending on cycle frequency. The coupling supports CIP and SIP, with O‑rings rated for steam sterilization to 150°C (short‑time). Zero‑dead‑leg design ensures cleaning solutions and steam reach all wetted surfaces.

DIN 11864-1 Aseptic Male Hose Coupling

• DIN11864 aseptic fittings meet the exacting needs of food, chemical and pharmaceutical industries.
• Available with optional lengths to suit Orbital and Manual Welding, these unions have been designed to match tube and pipe specifications in DIN 11850; ISO 2037, ASME BPE 2002 and BS 4825 Part 1 and also ISO 1127 for schedule pipe.
• DIN11864-1 union consists of four parts: Nut, Male, Liner and Gasket.

Product Description