Sucess Story | Exclusive development
Solenoid valves for dialysis machines from Fresenius Medical Care
90,000 dialysis machines were installed worldwide in 2020 – and the trend is rising. Solenoid valves are key components for these devices. To meet this demand, Fresenius Medical Care relies on the valve specialist RAPA Healthcare. In exclusive cooperation with Fresenius Medical Care, RAPA Healthcare has developed an innovative special valve for dialysis machines. The media-separated special valve is used as an inlet and outlet valve on the balance chamber. The valves open or close the inlet and outlet of the dialysis fluid system and ensure function and tightness in both flow directions and in the entire pressure range. The media is separated by an elastomer bellows.
Hämodialyse-Gerät 6008 von Fresenius Medical Care
Dual sourcing with RAPA Healthcare
Every second dialysis machine manufactured worldwide comes from Fresenius. Fresenius Medical Care is the technology and market leader in dialysis therapy. Dialysis machines consist of around 8,000 components. Key components are also solenoid valves, which must work with absolute precision and reliability in the hydraulic circuit. And that over a long period of around 5,000 operating hours per year with an average service life of ten to twelve years. They must be resistant to high temperatures, acids and bases. Depending on the appliance, around 30 to 50 valves are installed per appliance.
Although Fresenius Medical Care has its own in-house solenoid valve production, the company brought another valve specialist on board: RAPA Healthcare. In this way, Fresenius can guarantee security of supply, which can be a lifesaver in times of crisis. The multi-track approach makes the Group’s supply chain much more robust.
Order-related production
As RAPA only produces to order, the valve specialist was predestined for this task. The company, based in Selb, Franconia, was able to further develop and produce the product according to Fresenius’ specifications and in the desired quality. The basis of the collaboration, which has existed since the early 1980s, is exclusive development and production. In 2016, RAPA started production of the second generation of valves on a new, fully automated production line developed in-house. The plant produces around 500,000 valves per year in seven stations and has reserve capacity. Since then, the new dialysis valve type DV114 – in different versions – has been supplied in series by RAPA. The media-separated solenoid valve was specially developed for use in dialysis machines and specifically for use in the dialysate circuit, where it is exposed to aggressive fluids.
In einem einzigen Dialysegerät finden je nach Modell zwischen 30 und 50 dieser innovativen Ventile Verwendung
Partnership for more security
Demand is rising rapidly: kidney disease and the need for dialysis therapy is increasing worldwide. This is also shown by the rising production figures for dialysis machines at Fresenius Medical Care. While around 100,000 appliances were built between 1979 and 1999, the 500,000th machine rolled off the production line at the Schweinfurt site in 2012. And of the estimated 90,000 devices installed worldwide in 2020, around 48% came from Fresenius Medical Care. As a result, more and more valves are being installed. Like the devices, these must be optimized regularly. The production processes also have to be constantly adapted to the increasing demand and the high requirements for medical products. Due to the high cost pressure in the healthcare sector, RAPA Healthcare is faced with the demand from Fresenius for increasing flexibility and efficiency.
“The solenoid valves jointly developed by RAPA Healthcare and Fresenius Medical Care and produced by RAPA fit perfectly with our commitment to provide high-quality products and services to offer our patients the best possible care.”
Thomas Peter, Senior Commodity Buyer
Partnership for more security
Demand is rising rapidly: kidney disease and the need for dialysis therapy is increasing worldwide. This is also shown by the rising production figures for dialysis machines at Fresenius Medical Care. While around 100,000 appliances were built between 1979 and 1999, the 500,000th machine rolled off the production line at the Schweinfurt site in 2012. And of the estimated 90,000 devices installed worldwide in 2020, around 48% came from Fresenius Medical Care. As a result, more and more valves are being installed. Like the devices, these must be optimized regularly. The production processes also have to be constantly adapted to the increasing demand and the high requirements for medical products. Due to the high cost pressure in the healthcare sector, RAPA Healthcare is faced with the demand from Fresenius for increasing flexibility and efficiency.
Vollautomatische Fertigungs- und Montagelinie am RAPA Standort in Selb
Precision – RAPA and Fresenius on the way to increased efficiency and perfection
RAPA’s technical team meets the increased quality requirements and the demanding specifications of the customer in terms of functional reliability, freedom from maintenance and reliability, given the long service life of the component. Only selected materials are used in the DV114 media-separated solenoid valve. The robust and compact construction and design offer potential savings in terms of material and space. Together with Fresenius, RAPA is working on optimizing processes and structures in order to coordinate them as well as possible. The result: a functioning integration of RAPA Healthcare into the process chain at Fresenius to reduce costs and save time for efficient cooperation. The primary goal of the company partnership is 100 percent delivery reliability and zero-defect production.
