Modular pipework vs traditional: a buying guide for manufacturing businesses

Pipework is a critical component in many manufacturing businesses. Efficient, reliable versions can support productivity, improve safety and hygiene and help reduce costs in the long term. In recent years, modular systems have become an increasingly popular alternative to more traditional welded or flanged pipework.

In this article, we will discuss the advantages and disadvantages of modular components, how they compare to traditional methods, and why the unique properties of the quicker release and connect systems can benefit many modern applications.

Traditional pipework: reliable, but inflexible

For decades, pipework and steel ducting have been designed and installed as permanent, bolted or welded infrastructure. The conventional approach has the following advantages:

l Strength: welded joints are strong and reliable, and when done correctly, have a low risk of leaking.

l Robust: large welded installations are stable and can handle high pressures, vibrations, or temperature fluctuations.

l Familiar: most technicians and engineers are familiar with welded or flanged systems, meaning the tools and skills to fabricate and install them are widely available.

However, this approach also has significant downsides:

l Labour intensive: welding and bolting flanges requires a high degree of manual work and skilled labour is often needed.

l Fixed: traditional pipework is designed to be permanent. If the layout needs to change, new sections have to be cut, ground and welded.

l Downtime: taking a pipework installation apart for cleaning, inspection, or upgrades can require extensive time in shutdown.

In some cases, this type of traditional pipework is still the right choice. If a system is static, with little need for change or movement, and must have a high degree of reliability, more conventional solutions may be best. However, where businesses value flexibility, hygiene, or operational efficiency, modular alternatives can have a significant impact.

Modular alternative: simplicity and strength

Compared to welding or bolting, this method of connecting pipe sections and a cyclone dust separator has numerous advantages. The components of a modular system are connected by opening, inserting and closing. Skills and work are minimal compared to welding. The systems can be assembled, dismantled, moved, or reconfigured easily and changes do not require lengthy downtime.

The right seal profile, combined with a torque-adjusted pull-ring, creates a reliable, leak-tight connection and because modular systems can be taken apart and moved, pipework can be reconfigured to match changing production needs. This creates faster assembly, disassembly and reconfiguration, resulting in lower labour costs and less operational disruption.

The disadvantages

Modular systems provide numerous benefits, but there are also potential challenges and limitations that should be considered. A system assembled with standard seals and pull-rings is typically rated for shock and explosion protection of 1–3 bar. For systems subject to high pressure or flammable media, other precautions may be needed. Seals can be sensitive to wear or damage, especially in high temperatures, abrasive materials, or hard chemicals, therefore regular inspection and replacement may be required to maintain tightness.

Because modular systems require specific standards, businesses should ensure that they can source replacements when needed. And finally, while labour costs for modular systems are lower, the initial cost of components can be higher.

Modular vs traditional: which one to choose

In many cases, the decision of whether to use modular or traditional pipework will come down to the specific needs of the business. Permanent systems that must be completely reliable, for example, heavy-duty, high-pressure infrastructure may still use welded or bolted pipework.

However, in most other cases — especially in adaptable manufacturing environments, for example, in food and beverage, pharmaceuticals, or any business where hygiene, fast cleaning, or frequent changeovers are important — modular components will offer clear advantages. They are easy and quick to dismantle, inspect, clean, and reassemble. Open, attach, and close! Teams can work quickly without having to sacrifice the safety and tightness of traditional welded systems.

Special concerns for particular industries

Food and beverage production is an area where the advantages of modular systems are particularly clear. Hygiene is often a primary concern in this sector, with regular cleaning cycles required. In many cases, entire sections of pipework may need to be dismantled to allow for cleaning. Modular components allow this to be done quickly, and systems can be reassembled or moved with a minimum of effort. Modular ducting and pipework also allow for flexibility in production lines, which can be a big advantage when changing products or production schedules.

The production of pharmaceuticals is another area where hygiene and system cleanliness are key. Combined with the need to rapidly adapt systems, the ability to quickly change layouts using modular components can be a significant advantage. The safety of seals and pull-ring connections is also helpful, particularly in sterile environments.

Efficiency through agility

For modern manufacturing, efficiency is often linked to agility. Systems that can be quickly adapted, inspected, or changed can dramatically reduce downtime, support faster changeovers, and help businesses become more reactive. The conventional approach to pipework and ducting is reliable but slow and cumbersome to change. Using the modular method can be a faster, more flexible way of handling air and products.