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PUMPS, VALVES & ACTUATORS DRINKING IN CONTROL VALVE BENEFITS


Bürkert’s ELEMENT modulating control valves have helped a UK brewery secure improved productivity and reliability


hether bitter, ale, lager or craft – the incredible choice of beers makes competition between brewers fierce. To gain share in a saturated market and meet consumer demand, breweries need production equipment such as control valves to operate with the utmost reliability. Consequently, when a UK brewery noticed its mechanical interface modulating control valves were becoming maintenance intensive, it approached Bürkert for a better solution. Brewing is a complex process encompassing hop and grain selection, mashing, boiling, heating, cooling, fermentation and bottling – and valves play a crucial role in delivering the perfect bottle, can or pint.


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washdowns can also clog the mechanisms, reducing performance. The brewery was suffering from all these


At the UK brewery, an array of modulating control valves was responsible for regulating various processes such as glycol supply to the chillers, steam control to the heat exchangers, as well as CO2 and O2 supply for fermentation and storage. The equipment was subjected to regular chemical washdowns, and the need to meet supply agreements placed high operational demands on the whole process, including the valves.


Traditional modulating control valves have their limitations. First, mechanical wear on components can compromise valve accuracy over time, affecting processes and overall product quality. Chemicals from repeated


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issues, resulting in deteriorating valve accuracy and increasing failures. While repair work could be completed during scheduled maintenance, the valves were becoming a time sink, with every planned shutdown dedicated to fixing them. Diaphragm actuators in the valves were adding to the problem, as they were not suitable for use with ingredients used in the brewing process. The situation increased operating expenditure (OPEX) – a position operators couldn’t tolerate. Looking for a long-term solution, the brewery approached Bürkert. After dialogue with the customer, Bürkert recommended its ELEMENT range of pneumatically actuated continuous control valves – which directly addressed the limitations of the previous equipment.


A HAT-TRICK OF PUMP ORDERS IN SUGAR PROCESSING APPLICATIONS


ollowing the proven, ongoing performance of three rotary lobe pumps installed at a sugar refinery, a further two units from Börger are to be installed at the plant. Two of the existing Börger pumps are utilised for white mass (sugar syrup with crystals), whilst the third pump also runs 24/7 (from August to May), but for a slightly lower grade of sugar. Both applications send the highly viscous solution (50-55% solids) to its final stage, where the syrup is spun off to reveal the end-product of fine white sugar crystals. Increasingly prohibitive maintenance bills (over £12,000 per overhaul, per pump) and lengthy downtime had prompted the sugar refinery to replace three of its pumps. The sugar refinery also ensured that the new pumps are all the same size (unlike the previous units), to reduce the cost of required spares.


A further four Börger pumps have also become an integral part of the sugar producer’s AD plant, which uses waste pulp beet as a feedstock for clean renewable energy. The AD plant includes three digesters, receiving around 100,000 tonnes of pressed sugar beet pulp pa. The Börger pumps are utilised for the transfer of digestate.


At a separate sugar-beet processing facility, a Börger BLUEline EL 1000 pump has been installed after an old rotary piston unit failed. The Börger pump conveys massecuite (sugar crystals), with flow rates of 60 – 150 GPM @ 52 psi.


And to complete a hat-trick of new orders in highly viscous and abrasive applications such as the processing of magma, sugar syrup, and liquid sugar, a Börger BLUEline EL 1000 pump is unloading molasses (10,000 cP) from rail tankers.


www.boerger.com


Kieran Bennett, Industry Manager, Food & Beverage at Bürkert, explains why: “These valves are fully sealed and feature air recycling technology, which prevents ingress of ambient air, chemicals and contaminants. The clean dry air used to pressurise the actuator is fed back into the spring chamber via a pilot valve, which helps to prevent internal contamination and corrosion. This ensures a long service life.


“A contactless position control system eliminates wear and clogging issues. The piston actuator is smaller and lighter, while offering better compatibility with brewing processes than competing diaphragm designs. Users can expect 0.1% accuracy over seven million cycles, more than three times longer than conventional alternatives. An LED digital display on top of the valve also provides key process information to operators.” Specifically designed for hygienic environments, the ELEMENT valves feature a stainless steel exterior for ease of cleaning and inherent chemical resistance. With an IP67 rating, the design is ideal for production environments with regular washdowns. The system installed at the brewery included digital leakage alerts, as well as intuitive read-outs for flow, temperature, pH levels and operating pressure.


Bürkert began the process of replacing all the brewery valves around five years ago, and during that time, the new replacements have required no maintenance. This has saved time, allowing brewery staff to engage in other projects, and reduced OPEX, improving overall profitability. Additionally, Bürkert has provided the customer’s engineering team with training regarding the maintenance process for the new valves.


Bürkert Fluid Control Systems https://www.burkert.co.uk/en/Landingpage/ long-life-and-long-term-accuracy-for- continuous-control-valves


JULY/AUGUST 2024 | PROCESS & CONTROL 37


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