Case Study: Precision Swaged PFA Tube Assembly for Pharmaceutical Application

Project Overview

Adtech was approached to manufacture a precision PFA tube assembly for use within a pharmaceutical processing environment. The application demanded a smooth internal and external transition between differing tube diameters, eliminating potential areas for bio-burden build-up while maintaining full material performance at elevated temperature.

The final component measured 550mm in overall length and incorporated two critical fused transitions.

Technical specification

The assembly consisted of:

• PFA Tube 7/8” ID x 1” OD fused to PFA Tube 5/8” ID x ¾” OD
• PFA Tube 7/8” ID x 1” OD fused to PFA Tube 3/8” ID x 1/2” OD
• Ultra-short, smooth swaged transitions between tube sizes
• Overall length: 550mm
• Material: Standard purity grade PFA
• Maximum working temperature: +260°C

The primary technical challenge centred on achieving the shortest possible swaged transition while maintaining a uniform, smooth bore and outer surface profile.  This was particularly challenging as the smaller diameter tube to be fused were of 3 differing dimensions, while the larger tube diameter remained the same.

Engineering Challenge

Pharmaceutical applications impose strict requirements on fluid path design. Any abrupt step, cavity or surface irregularity can create areas where product residue may accumulate, increasing contamination risk.

The customer required:

• A continuous, smooth internal flow path
• Smooth external geometry
• Dimensional consistency across small batch production
• A design suitable for repeat manufacture

Achieving this in PFA, while maintaining structural integrity and temperature capability — required controlled fusion and precision swaging processes.

 

Adtech’s Solution

All tooling and processing methods were designed and produced in-house by Adtech’s R&D team. This approach allowed:

• Full control over fusion parameters
• Precise swage profile development
• Minimised development costs
• Efficient manufacture of small batch quantities

By controlling the swaging process, Adtech produced a compact, smooth transition that met pharmaceutical hygiene expectations without compromising mechanical performance.

Production & Scalability

Initial orders were placed in small batch quantities. Following successful validation in application, the customer has placed repeat orders.

Because all tooling and processing routes were developed internally:

• Batch production can be repeated with consistency
• Tooling costs remain controlled
• The process can be scaled as demand increases

This project demonstrates Adtech’s capability to convert complex fluoropolymer design challenges into manufacturable, repeatable solutions.

Outcome

The finished PFA tube assembly delivers:

• Smooth internal and external transitions
• Suitability for pharmaceutical-grade environments
• Continuous performance at temperatures up to +260°C
• Repeatable small batch manufacture with scalable production potential

This case reinforces Adtech’s expertise in precision fluoropolymer fabrication, fusion and value-added tube processing for critical applications.

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