Two ways to control nitrogen: simple or intelligent

However, there are clear limits:

• Hardly any flexibility: changes in nitrogen requirements are difficult to map.
• No reaction to pressure fluctuations: if the input pressure drops, the flow rate drops too and go unnoticed.
• No monitoring: it is not possible to monitor the flow or to gather data

Please note: if you still want to record measured values at a later date, additional hardware is required (e.g. separate pressure or flow sensors and the necessary input on the controller), which increases the costs and system complexity. Despite the very long service life and reliability of simple switching valves such as the MH1, they are not ideal for processes in which cleanliness is critical. Their design means that higher particle emissions are to be expected compared to dedicated mass flow controllers.

However, many production lines continue to rely on this principle, especially when only simple volumetric flow rates need to be kept constant and appropriate filters reabsorb the particles. But as soon as dynamic adjustments, reliable monitoring or process traceability are required, this solution quickly reaches its limits.

The products themselves are not "intelligent" in that they can autonomously detect anomalies but they are AI-ready. In conjunction with filter monitoring, pressure sensors and algorithms, the degree of pollution of filters can be detected, for example, which enables timely servicing without interrupting production.

What are the different type of valves and what are they suitable for?

Before deciding on a specific valve, you should take a close look at the technical requirements and the application environment. Each valve has its own strengths, be it in terms of flow rate, size or connectivity.

Why more expensive is sometimes cheaper

While simple systems appear to be significantly cheaper to purchase, reliable regulators with a monitoring function offer decisive advantages:

• Process reliability: fluctuations in the input pressure do not lead to fluctuations in the flow rate
• Real-time feedback: ideal for predictive maintenance and internal consumption measurement
• Scalability: anomalies can be detected immediately, especially on complex lines with many control points
• Total cost of ownership: precise systems regulate the flow rate to the exact level required, which saves nitrogen and ultimately leads to a reduction in energy consumption and CO2 footprint.

Example: in a system with 50 regulators, a simple display on each device can help to quickly identify defective points without a digital readout.

Perspective: ready for AI & predictive maintenance

Modern mass flow controllers provide valuable data – flow rate, pressure, temperature – which can be integrated into higher-level systems such as Festo AX. This opens up possibilities such as:

• Determining consumption for cost centres
• Monitoring filter wear through pressure difference
• Maintenance predictions based on real load data

These products are not "intelligent" per se, but they are AI-ready and form the basis for future-proof, data-supported manufacturing processes.

Support with making decisions: the right solution for your process

Choosing the right valve depends on many factors:

• Required flow rate range
• Energy consumption
• Process requirements (e.g.. cleanroom class)
• Integration into existing controllers
• Requirements for monitoring and readouts

To make tailored recommendations, we will be using an interactive tool in the near future. This will ask specific questions and then suggest the optimum solution, from a simple orifice to an AI-enabled VEFC.

Conclusion

Regulating nitrogen in semiconductor production is much more than a technical side issue; it influences quality, process stability and costs. The decisive factor is always what your application requires, whether that is a simple solution or state-of-the-art control technology. With the right choice, you not only ensure operational safety, but also efficiency and future viability.