All-welded heat exchangers
Zero gaskets, zero mechanical seals, zero dead zones. The fully welded tubular circuit eliminates every common source of leakage and cross-contamination in continuous flow systems.
ULTIMATE - Industrial decontamination unit
The standardized, ultra-compact continuous flow solution for bio-industries and laboratories
The patented ULTIMATE unit brings the performance of a fully custom continuous flow decontamination system to facilities that need it fast, at a standardized price, and without the complexity of a bespoke engineering project. Designed for bio-industries and laboratories, it combines all the essential functions of a high-grade continuous decontamination system, including containment, treatment validation, and energy recovery. These features are packed into an ultra-compact, stock-available unit that is ready to deploy from day one.
- Capacity: Up to 4,200 gallons per day (16,000 l/day)
- Technology: Continuous
- Energy: Steam
- Effluent BSL: BSL1, BSL2, BSL3
Produced in series, available from stock, and eligible for fast-track delivery. Fully operational as soon as connected to your utilities.
The standardized path to continuous flow decontamination
For facilities transitioning from batch systems to continuous flow treatment, or scaling up from lab-range units to production-grade infrastructure, the biggest barrier is rarely technical, it is the time, cost, and complexity of specifying, engineering, and qualifying a fully custom system. Detailed URS development, extended lead times, site-specific engineering studies, and lengthy FAT and SAT processes can push the timeline from project approval to operational system well beyond what production schedules allow.
The ULTIMATE was designed to remove that barrier entirely. By standardizing all the essential functions of a high-performance continuous flow decontamination system into a single, pre-validated platform, produced in series and available from stock, Actini has created a route to continuous flow decontamination that is faster, simpler, and more cost-effective than any custom alternative, without compromising on treatment performance, containment integrity, or regulatory compliance.
All the essential functions, nothing superfluous
The ULTIMATE’s design philosophy is built around one principle: include everything a facility genuinely needs to decontaminate, contain, and safely release biohazardous effluent and nothing more. The result is an ultra-compact system at 32″ x 56″ x 87″ that integrates a starting tank, CIP preparation circuit, pumping system with filter, all-welded tube-in-tube heat exchangers with energy recovery, and a fully instrumented control system into a single one-piece skid.
Every connection in the effluent circuit is fully welded, eliminating gaskets and mechanical seals as potential leakage points. The tube-in-tube heat exchanger geometry generates turbulent flow and eddy diffusion to ensure uniform heat distribution across the entire effluent stream. This guarantees consistent decontamination performance at every point of the circuit simultaneously. With 80% of the thermal energy recovered from the treated effluent used to pre-heat incoming effluent, the ULTIMATE delivers high-throughput continuous decontamination. This process operates at a fraction of the energy cost of systems without recovery.
Fast-track delivery for time-critical projects
When production timelines cannot wait for custom engineering cycles, the ULTIMATE’s standardized design and stock availability accelerate delivery. This delivers a fully functional, pre-validated continuous flow decontamination system to your facility on a schedule that meets your project needs. Standard qualification documentation is included with every unit, further reducing the time from installation to operational release in regulated environments.
Key Highlights
80% energy recovery
Counter-current heat exchange recovers thermal energy from treated effluent to pre-heat incoming effluent, dramatically reducing steam consumption per gallon treated and lowering both operating costs and environmental footprint.
Guaranteed decontamination
Turbulent flow conditions within the tube-in-tube heat exchangers ensure uniform heat distribution across the entire effluent stream, with no cold spots and no risk of undertreated effluent reaching the discharge point.
Fully automatic, zero operator intervention
The system starts based on a level sensor, runs its treatment sequence, stops, and washes automatically, with no manual intervention required at any stage and full PLC monitoring throughout.
Emergency shutdown on hazard detection
Strict safety devices including an emergency shutdown valve activate automatically in the event of any dangerous parameter deviation, preventing discharge of untreated effluent under any failure scenario.
Standard qualification documentation included
Protocols and procedures for fast qualification are included as standard, reducing time to operational release in GMP-regulated facilities.
Decontamination cycle
- Heat treatment with F0 > 25 depending on the required safety levels
- 176°F to 275°F (80 °C to 135°C) for 1 minute
- Recommended daily operation: up to 16 hours per day
- Guaranteed decontamination through eddy diffusion (turbulence)
- Validation of the treatment temperature and efficiency by sensors
- Ensured containment of contaminated effluent with strict safety devices such as emergency shutdown valve in case of dangerous event detection
Design
- Tubular design allowing continuous treatment of large volumes of biowaste effluent
- Ultra-compact design: W: 32” – L: 56” – H: 87”
- All welded heat exchangers to avoid any risk of leakage and cross-contamination
- Energy recovery section to pre-heat and pre-cool biowaste effluent (savings of 80% of heat energy used)
- Compliance with American standards
- Starting tank and CIP (Cleaning in Place) preparation
- CIP tanks for CIP solutions storage (Cleaning in Place)
- Pumping system secured by a filter
- Treatment section with energy recovery system
- Fully instrumented system (temperature sensor, flowmeter, pressure and level transmitters, valves) for total automatic operation of the unit: it starts based on a level sensor, stops and washes without any intervention
Available options
Performance & Safety
Effluent Holding Tank For facilities lacking upstream collection, an integrated holding tank buffers incoming effluent volumes. This maintains a consistent feed to the ULTIMATE, regardless of how much upstream generation rates fluctuate.
Cooling by Tubular Exchanger For installations where additional outlet temperature control is required beyond the standard energy recovery cooling, an extra tubular exchanger ensures consistent treated effluent temperatures under demanding operating conditions or high ambient temperature environments.
Neutralization System For facilities where treated effluent pH must meet specific discharge standards before entering the drain system, an integrated neutralization system automatically measures and adjusts pH at the outlet, ensuring full compliance with local effluent discharge regulations without manual intervention.
Maintenance & Traceability
Cleaning in Place Skid The automated CIP skid provides complete cleaning of the entire ULTIMATE system through a fully automated sequence, with no manual disassembly required. Chemical solutions are prepared, circulated, and discharged automatically, keeping the system in peak operating condition and audit-ready at all times.
Manual Cleaning in Place For facilities where a fully automated CIP skid is not required, the manual CIP option provides the connection points and circuit design needed to perform thorough internal cleaning of the system with manual preparation and initiation of cleaning cycles.
Why Choose Actini?
At the industrial scale, the consequences of a decontamination failure extend far beyond a compliance citation. Indeed, they affect production continuity, public health, and your facility’s operating license. To address this, Actini provides the engineering expertise and proven track record to ensure those risks never materialize.
Furthermore, with hundreds of large-scale systems installed in vaccine manufacturing facilities, government research campuses, and biotech production sites across the US and worldwide, facilities trust Actini when getting it right is the only acceptable outcome. Ultimately, ISO 14001 certification and a “Made in the USA” manufacturing standard 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.