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Industry Trends in More Sustainable Manufacturing

Companies which previously only talked about sustainability are now taking action and investing money to achieve long-term sustainability goals

Looking back about 5-7 years ago, there was a lot of talk about sustainability and efficiency, but the follow-through with action accompanying the interest or intent was slow to follow. Requests for next generation process automation devices were plentiful, but after the quote was issued there was little forward momentum toward actual implementation of these technologies. Today we are not only seeing advancement in the requirements of the capabilities of the devices themselves, but preferences for the more sustainable production of these products & systems. Bottom line is that companies which previously only talked about sustainability are now taking action and investing money to achieve long-term sustainability goals.

 

From both large and small companies, there is forward momentum toward increased investment in smarter technologies that provide continuous feedback, monitoring and traceability on utilization of resources like energy, water - and believe it - or not compressed air.

Type 8692

Digital electro-pneumatic positioner for integrated mounting on process control valves

Type 8692
  • Compact and robust stainless steel design
  • Easy start-up with automatic X-Tune function
  • Contact-free position sensor
  • Integrated pilot air duct with spring chamber aeration
  • EtherNet/IP, PROFINET, Modbus TCP, PROFIBUS DP-V1 or Bürkert system bus (büS)

 

Type 8693

Digital electropneumatic process controller for integrated mounting on process control valves

Type 8693
  • Compact and robust stainless steel design
  • Easy start-up via Tune function for position and process controller
  • Contact-free position sensor
  • Integrated pilot air duct with spring chamber aeration
  • PROFIBUS DP-V1, EtherNet/IP, PROFINET, Modbus TCP or büS (Bürkert System Bus)

 

Type 8694

Digital electropneumatic positioner for integrated mounting on process control valves

Type 8694
  • Compact and robust stainless steel design
  • Start-up with automatic TUNE function
  • Contact-free position sensor
  • Integrated pilot air duct in the actuator
  • AS interface, IO-Link or Bürkert system bus (büS)

 

Type 8696

Digital electropneumatic positioner for integrated mounting on process control valves

Type 8696
  • Compact stainless steel design
  • Start-up with automatic TUNE function
  • Contact-free position sensor
  • Integrated pilot air duct in the actuator
  • Digital communication IO-Link, Bürkert system bus (büS)

 

Further still, when products are manufactured domestically, it is preferred and not simply because of programs like the BABAA Act (Build America, Buy America Act), but also related to the ecological sourcing and transportation of goods. Companies are taking a serious look at equipment that can deliver precise control. The motivation here is there is efficiency & resource savings in precision. Devices that control to a tighter tolerance utilize fewer utilities. Additionally, devices that simply take less energy to operate are obvious targets.

Type 2036

Robolux multiway diaphragm valve, pneumatically operated

Type 2036
  • Extremely compact and space-saving design
  • Reduced installation costs
  • Reduced number of valves and welds

 

One example is the 80% energy savings delivered by Burkert’s Kick-and-Drop solenoid technology which utilizes a double wound coil to generate the required inrush power that the valve needs in order to open. After approx. 500 milliseconds, the Kick and Drop electronics assembly switches to an energy-saving holding power drastically reducing power consumption.  

 

Alternatively, the fit for purpose considerations of electromotive control valves that use electrical actuation in place of a pneumatic actuator eliminate need for compressed air entirely, which can be about 8 times more expensive to generate. 

 

Type 3360

Electromotive 2-way angle seat control valve

Type 3360
  • Good and fast control
  • Weather, impact and vibration resistant design
  • Easy cleaning by its design according hygienic demands
  • Position controller and process controller available

 

Type 3361

Electromotive 2 way globe control valve

Type 3361
  • Highly precise, dynamic closed-loop control
  • Several Kv values per port size due to removable valve seats
  • Weather, impact and vibration resistant design
  • Easy to clean thanks to the hygienically designed surface
  • Position controller and process controller available

 

More compact solutions: block style manifolds and complex piping flow paths that allow for more accurate and efficient control of applications like process heating and cooling, CIP (clean-in-place) cycles, and faster switching between media. There is a blended approach to using electric control and pneumatic actuation in the same process control loop based on which is more effective to provide the desired results.

 

Precise control of critical process systems is a means to optimize system efficiency.  For example, when looking to control a heating or cooling process, the faster that system can be stabilized and the more tightly it can be maintained, the more efficient it is overall.  When precision capability is combined with lower energy consumption by the devices themselves, there is a direct, and very desirable impact to not only sustainability initiatives, but return on investment/total cost of ownership as well.
8840 3280 3285

 

Type 8840

Modular process valve cluster - distributor and collector

Type 8840
  • Valve cluster ready for installation
  • Compact design without any potential leakage
  • No assembly effort
  • No piping between the valves needed
  • Trusted actuators for simple automation

 

Type 3280

Electromotive 2-way globe proportional valve

Type 3280
  • Actuator is not wetted
  • Excellent setting range and fast reaction time
  • Low electrical power consumption
  • Connection orifice DN 8...15
  • Variants: standard, positioner, process controller and high-pressure variants for up to 22 bar

 

Type 3285

Electromotive 2-way globe proportional valve

Type 3285
  • Actuator isolated from flow path
  • Excellent range and fast response times
  • Low power consumption
  • Connection orifice DN 15...25
  • Variants: standard, positioner, process controller

 

Initial start-up costs always seem to be a barrier to entry, but more and more, we are seeing industrial automation projects looking further into the future toward total cost of ownership. There are variables taken into consideration today that didn’t seem to be as important just a few years ago, not simply focused on waste reduction but almost toward excess prevention. Factors including start-up time, replacement/servicing are being added to the more traditional considerations for lean manufacturing and waste reduction.

Type 8098

FLOWave SAW flowmeter

Type 8098
  • No obstacles inside the measuring tube, compact, lightweight and low energy consumption
  • Conforms to hygienic requirements, CIP/SIP compatible
  • Ideal for liquids with low or no conductivity
  • Digital communication, parameterisation via Communicator, display
  • Optional: ATEX/IECEx certification, II 3G/D

 

Companies are already tracking and aware of ways that they can reduce waste and usage, but adoption can be slow and takes time. We are going to see a more rapid acceleration happen as the companies that were just dipping their toes in the water a few years ago are seeing the real win-win benefits associated with the slightly higher initial investments. This doesn’t even approach the possibilities of further inclusion of AI in control solutions, which is best left for another discussion, but coming along quickly.

 

 

 

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