FOOD & BEVERAGE INDUSTRY FOCUS


TAKING CONTROL OF AUTOMATION I


Creating an application-specific automation solution to help food & beverage manufacturers remain competitive and comply with regulations requires considerable expertise says Bürkert


ncreasing competitiveness and higher levels of regulatory compliance are


placing greater demands on the food and beverage industry; improving automation levels and plant integration can address these concerns. However, creating an automation solution that is specifically matched to the application requires considerable expertise. The industry must maintain some of the highest hygiene standards while delivering high volume production systems. In addition, competitive forces demand that a business is efficient both in terms of the raw materials consumed and cost of manufacturing. Delivering these objectives is crucial to remaining in the industry. All process manufacturing businesses


will have introduced automation to a greater or lesser degree in recent years with many looking at the next step; increasing efficiency and gathering the increasing amounts of data required for effective process management and traceability. Levels of efficiency are determined by the scale of the production facility, however improving the levels of automation within a process of any scale can deliver improvements to maintenance and production costs, reliability and quality. Improved control and monitoring reduces wastage of expensive compounds, provides improved production reliability while delivering the continuous data required to meet regulatory standards. By making significant reductions in costs a properly engineered production system can deliver high quality products in an efficient process. Many smaller systems and standalone equipment use a centralised control concept based around a cabinet that contains all of the necessary components to operate the control valves including PLC, network connections, input/output systems and valve islands.


DECENTRALISED PROCESS CONTROL In many cases, especially in larger facilities, working toward a decentralised system of process control can provide a number of benefits compared to the more traditional approach. This concept uses intelligent, pneumatically operated process valves at field level which can be equipped with all the required automation components such as a pilot valve with manual actuation, electrical feedback units and optical status indication, fieldbus interfaces and even positioners and


considered by the vast majority of OEMs as an essential part of manufacturing strategy that allows them to remain competitive in a rapidly changing global market. In practical terms this can deliver improvements such as reducing supply chain management costs while improving production agility and the use of internal resources. Bürkert manufactures over 100,000 different products, typically valves, actuators, sensors, controllers and combined devices. Applying these to scenarios that require specialist assemblies requires skill and experience and an imaginative approach. The Systemhaus combines all of these


attributes and assigns a team with the necessary skills and expertise to design, simulate, prototype, construct and test the finished product. Working closely with the client, this team has the ability to ensure the most efficient methods are used to develop an idea into the completed design. Using in-house manufacturing facilities


process controllers. To bridge the gap between centralised and decentralised automation concepts flexible pneumatic valve units and compact automation systems can be used. These are typically wall-mounted directly inside small, hygienically designed cabinets that can be installed close to the process in question. These small, pre-configured and standardised units eliminate the long runs to valves and field devices and can be easily kept clean. Every one of these scenarios will be


unique and that requires the manufacturer of the control panel to take an individual approach to each project. At Bürkert a network of specialist design and manufacturing facilities each known as a Systemhaus has been operating for several years to deliver precise fluid control systems designed to meet specific process requirements and regulatory standards. With a bespoke control system the


designers have to start from the ground up, working closely with the client to establish what will be delivered by the new system and how best to achieve it. Often existing technology and components will have to be integrated with unique parts and custom designs in order to achieve the best solution.The principle of outsourcing this type of project is


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Companies in the food & beverage sector are now in a position to reconcile the commercial necessity of a high degree of automation with hygiene and safety requirements


enables bespoke components to be created and matched to the application, reducing component count, installation time and cabinet size. Where necessary the control system can be housed in a stainless-steel hygienic EHEDG cabinet to locate the compact field control box right in the process area which shortens the distance to the process valves.


RECONCILING AUTOMATION WITH HYGIENE/SAFETY Companies in the food & beverage sector are now in a position to reconcile the commercial necessity of a high degree of automation of their production with the requirements of hygiene and safety. Thanks to their modular structure


control panels based on the latest technology can be adapted to suit many applications whereby such optimised solutions are always based on high quality, tried and tested components with a long service life. In Bürkert's central control cabinet solution each component is the product of cross functional mechanical and electrical engineering innovation and exacting laboratory testing. Combining these products with the


design expertise and industry experience of the Systemhaus ensures the optimum solution is delivered to every client.


Bürkert Fluid Control Systems T: 01285 648720 www.burkert.co.uk


IRISH MANUFACTURING | SPRING 2017 9


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