PC-MAY24-PG38.1_Layout 1 15/05/2024 12:32 Page 38
FLOW & LEVEL CONTROL
This setup from Bürkert is widening the functionality of the FLOWave and providing additional opportunities for manufacturers to make their batching processes more accurate and cost-effective
quality stainless steel and with no internal restrictions, the FLOWave sensor can address many of the shortcomings of other flow measurement devices in the hygienic sector. The FLOWave is also a vital part of precision batch mixing control systems with better than 1% variation. Working in combination with other Bürkert hardware, including process valves, batch controllers and a touchscreen, the process of designing and commissioning a batch sizing control system is simplified. One of the major challenges with batch sizing is setting up the equipment. With so many variables in an installation, it can be a complex and time-consuming process to
GO WITH THE FLOW IN BATCH MANUFACTURING
Kieran Bennett, Industry Manager, Food, Beverage, Chemical & Petrochemical at Bürkert, looks at the importance of process accuracy in batch manufacturing and explains how it can be achieved
atch manufacturing offers several advantages for producers of high- quality end products, and it is common in the pharmaceutical, food and beverage sectors. Quality control is of paramount importance, while achieving cost- effectiveness comes a close second. In these processes, the design of the batch sizing control system can have a significant impact on the quality of the end product. The essence of batch control is the measurement and transfer of a variety of fluids to one location where they can be processed and moved on to the next production phase. Measuring and verifying flow volumes is key to establishing a reliable and repeatable process where all of the ingredients are measured precisely. Batch sizing control requires four essential components: the batch controller, communicator software, valves and a flow sensor. In addition, there are a few optional extras, such as operator displays, input/output modules and cabinets that collectively complete the installation.
B
In hygienic applications there is an additional requirement for all the materials and designs to be optimised for cleanliness. Hygienic designs must be specialised for clean/steam-in-place (CIP/SIP) processes; the requirements mean non-contact flow measurement designs using ultrasonics, electro-magnetic and Coriolis technologies have come to the fore.
Batch control is based on a simple principle where a valve opens to allow a certain volume of liquid to flow before being closed. The opening time for the valve is managed by the flow controller and a flowmeter is used to measure the actual volume dispensed. A feedback loop can improve the accuracy of the process by comparing the theoretical volume with the measured quantity.
38 MAY 2024 | PROCESS & CONTROL
However, these designs have drawbacks which can make them unsuitable for some applications. Many of the fluids in the food and beverage or pharmaceutical industries present challenges for conventional flow meters, with many requiring a conductive fluid with laminar flow, free from entrained gases. Bürkert’s flowmeter uses surface acoustic waves (SAW) technology to overcome these traditional obstacles. Manufactured from high
manually install all the configurations and ensure that all the components are properly set up and working in harmony. However, Bürkert has designed its components to utilise digital communications, enabling them to recognise each other and complete a large part of the configuration automatically. The touchscreen is integral to this procedure, walking the operator through the remaining steps for a simplified process.
Once the system is operational, a crucial part of batch sizing is the ability to compensate for changes in the system that affect the quantity being dispensed. Raw materials can be expensive so over-dosing, even by a small percentage, soon adds up to significant costs that could be avoided. This is especially true in the pharmaceutical industry, where active ingredients and water for injection (WFI) all have significant costs. Bürkert’s system uses a feedback loop that measures the dispensed volume and adjusts the timing of the valve accordingly. For example, if the storage vessel for the dispensed liquid does not have pressure compensation, then as more fluid is used, the pressure will drop, which will result in the dosed volumes reducing.
Bürkert’s system utilises the precision measurements from the FLOWave to assess the accuracy of the batch size compared to the theoretical volume. This information is used in a continuous feedback loop, to auto- correct the opening time of the valve to compensate for changes in the system and assure continued accuracy.
A 7” touchscreen, located at the batching station, allows the operator to pause, stop and start the process. The seamless
communication between all the components ensures that both configuration and operation run smoothly.
Bürkert Fluid Control Systems
www.burkert.co.uk
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56
