Burkert side controllers help bring food plants into the digital age
It is common in many brownfield food processing sites that process control valves may lack built-in networking capabilities.
These legacy valves, often relying on analogue (4-20 mA) or pneumatic control, can pose challenges for modern automation and data integration. By not being able to take advantage of modern digital networking and fieldbus technologies, plant operators miss out on the data insights that such technology can provide.
Today’s consumer market and food safety regulations increasingly demand greater process visibility, making networked control highly desirable. Not having remote access to process valves also limits remote diagnostics, predictive maintenance, and integration into modern industrial control systems.
One solution is to replace all the valves with modern technology, including digital actuator controls, but this can be a costly capital expenditure and involves interruption to the process. A more cost-effective alternative is to retrofit the existing valves with smart positioners that support industrial networking protocols (such as IO-Link, EtherNet/IP, or PROFIBUS) and can add real-time valve position feedback and diagnostic data while maintaining the existing valve actuators.
Burkert offers a solution like this with its SideCONTROL range of digital positioners and process controllers for valves, making the transition to digital control efficient and straightforward.
An Australian food and beverage manufacturer recently utilised Burkert’s SideCONTROL devices to upgrade their existing Sampson valves to digital control via IO-Link. Bürkert supplied Type 8791 SideCONTROL positioners for nine existing valves and Type 8635 positioners for four valves in a Zone 2 hazardous area, providing the full PID control loop function in conjunction with a temperature sensor, thereby eliminating the need for a separate PLC.
Burkert’s SideControl positioners are ideal for food and beverage applications because they can be used in a wet environment, providing remote access for operators. In areas where it is not ideal for someone to service the valve directly, the side positioner can be used with a remote mount, away from the actual valve.
For vibration applications, such as baggers or packers, where vibration is used to move the media (such as dried milk powder), being able to place the positioner away from the valve also avoids it being affected by vibration.
In terms of energy efficiency, the SideCONTROL positioners’ dynamic actuating system doesn’t leak air when the valve is in a hold position, resulting in zero air consumption in controlled states.
The SideCONTROL positioners offer simple operation via a graphical display and keypad or a Burkert Communicator device, and fast start-up with their built-in X.TUNE function. Retrofitting does not involve any intrusion into the fluid process, and they are compatible with all common pneumatic valve actuators, recognising single- and double-acting actuators automatically.
Upgrading process control valves for digital connectivity in brownfield food and beverage sites enhances efficiency, reduces downtime, and ensures compliance with industry regulations. By leveraging retrofitting technologies, such as Burkert’s SideCONTROL positioners, food processors can modernise their control systems cost-effectively while preserving existing valve infrastructure.
Digital electropneumatic positioner SideCONTROL
- Compact and robust design
- Easy start-up using X.TUNE function
- Integrated diagnostic functions for valve monitoring
- Dynamic actuating system with no air consumption in controlled state
- IO-Link Port Class A & B, AS interface or Bürkert system bus (büS)
Digital electropneumatic positioner SideCONTROL
- Compact and robust design
- Easy to start up using X.TUNE function
- Integrated diagnostic functions for valve monitoring
- Dynamic actuating system with no air consumption in controlled state
- EtherNet/IP, PROFINET, Modbus TCP, PROFIBUS DP-V1 or Bürkert system bus (büS)
Digital electropneumatic Process Controller SideCONTROL
- Compact and robust design
- Start-up via the X.TUNE and P.TUNE function of the positioner and process controller
- Integrated diagnostic functions for valve monitoring
- Dynamic actuating system with no air consumption in controlled state
- EtherNet/IP, PROFINET, Modbus TCP, PROFIBUS DP-V1 or Bürkert system bus (büS)