Product Details Supplier Info More products

An upgraded production plant for fruit juice concentrate and other ingredients for beverages and food products now includes intelligent process valves from Burkert.

These valves are used by the drink manufacturer across the entire production area in a decentralised control solution with communications via an AS-interface (AS-i).As part of this solution, all hygienic seat valves controlling the product flow, on-off valves for the auxiliary circuits for water, steam, sterile air and cleaning are automated in a decentralised mode by means of intelligent valves.

With this decentralised system, the only tasks remaining with the central process control system are control and status monitoring, resulting in savings in overall system project costs and improved transparency in system operation.

The integration via the AS-i fieldbus means that the advantages of decentralised automation can be utilised to the full.

All that is required for power supply, feedback and communication is a two-wire cable connecting the PLC with up to 62 valves.

Each process valve is individually connected to the main compressed air supply line installed in the field, whereby these connections are kept as short as possible.

This reduces the number and length of tube and cable connections, as well as the number of required control cabinets to a minimum.

An additional benefit is that the colour status indicators of the valves can be clearly seen from anywhere in the plant, further improving the transparency of the process.

The status of each individual valve can thus be checked onsite, even from a distance.

Moreover, as the process valves can be manually operated through the pilot valves at the control head, the operation of the machine is made even simpler.

The reliability and efficiency of the of the decentralised automation system for production and auxiliary functions at the beverage plant, has resulted in the decentralised control model being applied to new sections installed to further expand production facilities for additives.

Today, the raw product intake unit, the homogenisation and pasteurisation station and the raw product distribution system are equipped with intelligent process valves from Burkert.

Angle seat and diaphragm valves control the flow of cleaning media, including acid, alkaline and water, as well as the steam and sterile air supply.

All the valves are equipped with an Element clean-line control head with integrated automation functions and AS-interfaces for communication via fieldbus.

’For the extension of the plant, we were able to pursue the decentralised automation concept across the entire system, using our intelligent valve systems,’ said Sebastian Kundel, segment manager hygienic processing at Burkert.

’As the operating and maintenance staff were already familiar with the fieldbus system and the connecting and wiring concept, the new plant sections could be commissioned without any difficulties.

’The practical integration at field level of automation functions in the pneumatic drivers of the process valves allows for a high degree of automation at minimum costs and ensures excellent transparency.

’Thanks to the modular design of the valve systems, customised automation solutions can be devised easily and quickly.

’This is due to the fact that Burkert offers not only process valves, but also digital electro-pneumatic positioners and process controllers that can be combined in the same manner to provide complete control valve systems,’ he added.

The intelligent valves units used at the drinks plant comprise a valve actuator and control head.

They are manufactured according to the EHEDG guidelines for hygienic design and easy cleaning.

The valve units feature the high IP protection required for the actual application and are manufactured exclusively from detergent-proof materials.

The IP protection is therefore not affected by long-term use under conditions of high air humidity, or by frequent cleaning with aggressive chemicals.

This is especially beneficial to valve nodes, as there is often a problem of detergent solution or water escaping through valve leakage, resulting in frequent cleaning of the immediate area to ensure consistent plant hygiene.

A further key feature of the Burkert intelligent valves, which ensures reliable, trouble-free operation, is the provision of an integrated control air inlet to the actuator chambers.

This ensures that the spring chamber of the pneumatic driver is supplied only with clean control air.

Moisture, dust and contaminants in the ambient air cannot enter the actuator units and this, in turn, effectively prevents contamination of the piston seals and corrosion of the drive springs by cleaning solutions.

This design means that there is also no risk of moisture from the spring chamber entering the feedback module or the control head along the spindle extension.

It also prolongs the service life of the driver and enhances the hygiene of the process.

As product cannot enter the driver, both the spreading of germs and contamination of the driver by mould are effectively prevented.

The risk of spores produced in the spring chamber being ejected into the ambient air at each switching process, which is a common problem with conventional valves, is thus eliminated.

Burkert Fluid Control Systems

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.Whether the application is filling, level, flow, pressure or temperature we have a solution and a uniquely comprehensive range of products to handle it, including solenoid, process and analytical valves, pneumatic actuation, sensors and controllers.

For Burkert it is not enough to simply offer individual products.Our aim is to provide complete system and application solutions that meet the specific needs of our customers.Tell us what you need and our engineers will find an appropriate solution using our vast experience and a wide range of services such as advice and engineering, installation, testing, and after-sales support.

Burkert’s global presence offers our customers an additional advantage.Products and systems are constantly developed and optimised according to international standards.Through this process synergy effects evolve which ensure technological leadership and competitive advantage

View full profile