Add capacity without adding complexity
ach EXT3000 extension module connects to the main skid with no new automation study, no new PLC programming, and no interruption to existing operations, just additional throughput on demand.
ULTIMATE PLUS - Industrial decontamination unit
The scalable, standardized continuous solution for large-scale bioproduction facilities treating
The patented ULTIMATE PLUS industrial decontamination unit was engineered for one purpose: delivering industrial-scale continuous capacity that grows with your production, without engineering it from scratch every time. Built around a modular architecture that connects up to three 790-gallon-per-hour extension modules to the main ULT-3000 skid, it scales from 2,600 to 50,700 gallons per day in standardized steps, with no new automation study, no new commissioning project, and no interruption to existing operations each time capacity is added.
- Capacity: Up to 50,700 gallons per day (192.000 l/day)
- Technology: Continuous
- Energy: Steam
- Effluent BSL: BSL1, BSL2, BSL3
Fully standardized for bio-industries without specific URS pre-requisites.
A system that grows with your production
In large-scale bioproduction, effluent volumes rarely stay constant. Capacity expansions, new production lines, additional fermentation suites, and increasing batch sizes all drive effluent generation upward, often faster than facility planning anticipated. Conventional decontamination solutions respond to this growth with a costly and disruptive cycle: specification, engineering, procurement, installation, and qualification of an entirely new system every time capacity needs to increase.
The ULTIMATE PLUS breaks that cycle entirely. Its modular architecture is built around a central ULT-3000 main skid to which up to three EXT3000 extension modules can be connected as capacity needs evolve. Each extension adds 790 gallons per hour (3,000 lph) of additional treatment capacity. Automation is controlled entirely from the main skid, no new automation study is required when connecting additional modules, and no new PLC programming or integration work is needed. The result is a decontamination infrastructure that scales in defined, predictable steps, on your timeline, at a fraction of the cost and complexity of a new system installation.
The same proven technology at every scale
Every configuration of the ULTIMATE PLUS, from the base ULT-3000 to the fully extended four-skid system, operates on the same all-welded tube-in-tube continuous flow heat exchanger platform as the ULTIMATE range. To ensure maximum integrity, all connections are fully welded, eliminating gaskets and mechanical seals from the effluent circuit. Turbulent flow conditions within the exchangers, specifically eddy diffusion, guarantee uniform heat distribution across the entire effluent stream at every flow rate. This ensures consistent F0 performance regardless of which configuration is in operation.
Moreover, the integrated energy recovery section recovers up to 80% of the thermal energy used in the decontamination process, pre-heating incoming effluent against the heat of treated effluent leaving the system. Ultimately, at the throughput levels the ULTIMATE PLUS operates at, this recovery translates into very significant reductions in steam consumption and operating cost per gallon treated, making it one of the most energy-efficient large-scale decontamination platforms available.
Operational safety at every scale
At industrial throughput levels, decontamination system failures trigger consequences far beyond simple compliance events. Consequently, we designed the ULTIMATE PLUS with this reality in mind.
For instance, an emergency shutdown valve activates automatically if any parameter deviates, preventing the discharge of untreated effluent under any failure scenario. Furthermore, in the event of a cycle failure, the system automatically diverts effluent back to the storage tank. This requires no operator intervention and eliminates all risk to the drain system or environment.
Similarly, for maintenance operations, a full automatic direct steam sanitization cycle can be performed to ensure operator safety before any access to the system’s internal circuit. In addition, the pumping system can be doubled for full redundancy, ensuring that a single pump failure does not interrupt production-critical decontamination operations. Finally, remote access capability allows authorized personnel to monitor and manage the system from any point in the facility.
Key Highlights
All-welded tubular circuit
Zero gaskets, zero dead zones, zero cross-contamination risk. Every connection in the effluent circuit is fully welded, eliminating the most common failure points in high-throughput continuous flow systems.
80% energy recovery
Counter-current heat exchange recovers the majority of thermal energy from treated effluent to pre-heat incoming effluent, delivering significant reductions in steam consumption and operating cost at scale.
Automatic failsafe on cycle deviation
Emergency shutdown valve and automatic effluent return to storage tank activate instantly on any dangerous parameter deviation, with no operator intervention required.
Single Automation platform for all configurations
All extension modules are controlled from the main skid's automation system, with no additional engineering required when adding capacity.
Automatic steam sanitization for maintenance safety
A full automatic direct steam sanitization cycle can be initiated before any maintenance access, protecting operator safety at every service intervention.
Model Range
Model |
Daily Capacity |
Technology |
Energy |
|---|---|---|---|
| ULT-3000 | 2,600 to 12,700 gallons | Continuous | Steam |
| ULT-3000 + EXT3000 (x1) | 7,900 to 25,400 gallons | Continuous | Steam |
| ULT-3000 + EXT3000 (x2) | 13,200 to 38,000 gallons | Continuous | Steam |
| ULT-3000 + EXT3000 (x3) | 37,000 to 50,700 gallons | Continuous | Steam |
Based on 16-hour-a-day operation. Systems can operate up to 24 hours per day depending on operating conditions.
Decontamination cycle
- Heat treatment with F0 greater than 25 depending on required safety levels
- 176°F to 275°F (80 °C to 135°C) for 1 minute (2 min. as an option)
- Capacity upgrades by connecting 790-gallon-per-hour EXT3000 modules
- Recommended daily operation: up to 16 hours per day
- Guaranteed decontamination via eddy diffusion ensuring uniform heat distribution
- Multi-point temperature and efficiency validation by sensors
- Automatic emergency shutdown valve on dangerous event detection
- Automatic effluent return to storage tank in case of decontamination cycle failure
Design
- Tubular design allowing continuous treatment of large volumes of biowaste effluent
- Ultra-compact design of the add-ons:
- Main skid: W: 27” – L: 98” (1,700 x 2,480 mm) – H: 93” (2,350 mm)
- Each add-on: W: 37” – L: 100” (940 x 2,530 mm)
- All welded heat exchangers to avoid any risk of leakage and cross-contamination
- Energy recovery section (savings of 80% of thermal energy used)
- Possibility to double the pumping system for redundancy
- Automatic operation controlled from the main skid: no automation study required when connecting add-ons
- For maintenance operations, the system performs a full automatic direct steam sanitization to ensure operator safety.
- Remore access
- Compliance with American standards
Available options
Performance & Safety
Effluent Holding Tank For facilities lacking upstream effluent collection, an integrated holding tank buffers incoming volumes before the treatment section. This ensures a consistent, controlled feed to the ULTIMATE PLUS, regardless of any fluctuations in the upstream generation rate.
Extension of Holding Time, 60 to 120 Seconds For effluents requiring extended thermal exposure to meet specific standards, the system extends holding time from the standard 60 seconds up to 120 seconds within the existing architecture.
Cooling by Tubular Exchanger Where you require additional outlet temperature control, an extra tubular exchanger maintains consistent treated effluent temperatures, even under high-throughput or thermally demanding conditions.
Pumping System Redundancy An integrated second pumping system operates in parallel with the primary pump to provide full redundancy. This guarantees that a single pump failure never interrupts your continuous decontamination operations.
Maintenance & Traceability
Cleaning in Place Skid The automated CIP skid cleans the entire ULTIMATE PLUS system through a fully automated sequence, eliminating the need for manual disassembly. The system automatically prepares, circulates, and discharges chemical solutions to maintain peak operating condition and audit-readiness between production campaigns.
CIP Tanks You can integrate additional CIP solution storage tanks to support higher-volume cleaning requirements. These tanks enable back-to-back cleaning cycles without interrupting operations for solution preparation.
Neutralization System For facilities requiring specific effluent pH levels for drain discharge, an integrated neutralization system automatically measures and adjusts pH at the outlet. This guarantees full compliance with local discharge regulations without manual intervention.
Why Choose Actini?
At the industrial scale, decontamination failures do more than trigger compliance citations; they jeopardize production continuity, public health, and your facility’s operating license. To address this, Actini applies its engineering expertise and proven track record to prevent these risks from ever materializing.
Furthermore, with hundreds of large-scale systems operating in vaccine manufacturing facilities, government research campuses, and biotech sites across the US and worldwide, facilities trust Actini when they demand perfection. Ultimately, our ISO 14001 certification and “Made in the USA” manufacturing standards back our commitment.
Our products are designed, manufactured, and sold locally: in the United States for our U.S. customers, and in Canada for our Canadian customers.
Ready to move to continuous flow?
The ULTIMATE delivers production-grade continuous decontamination on a standardized platform, available from stock, delivered fast, and operational from day one. Talk to our technical team today and find out which configuration fits your effluent volume, site constraints, and project timeline.