Incorporated 30 years ago in June this year, Cleone Foods produces Jamaican patties and distributes them under its Island Delight brand name. The company relies on it’s process equipment to ensure an uninterrupted supply of it’s tasty products and Burkert has proven itself up to the task with process valves that have been in operation for ten years before requiring a service.
Derived from the Cornish pasty, Jamaican patties can contain a range of fillings with a distinctive, spicy taste. The company, which is based in Birmingham, has expanded several times since its inception, including into bigger premises.
Wade Lyn, the founder and company director of Cleone Foods, created the company with a clear objective of creating a strong brand that delivered high quality products without compromise. This concept was also used in selecting the equipment used to manufacture the Jamaican patties and the reason behind choosing Burkert fluid control valves.
Wade says, “We have a passion for creating our products and quality matters a lot – not just for food industry regulatory standards but for the taste and the experience of our range, it has to be right.”
Maintaining productivity is very important in any industry, especially in the food and beverage sector, where downtime needs to be minimized wherever possible. Therefore, being able to replace components, such as control valves, in a matter of minutes ensures that production lines can continue operating with minimal delays.
For the past 10 years, Burkert Type 2000 flow control valves have been used to regulate the flow of steam and hot water to the cookers, in an area that has repeated wash-downs. The choice of control valve has delivered a decade of reliable service in an environment that would have caused lesser components to fall short.
More recently, the Type 2000 underwent a design update that, amongst other things, reduced the overall length of the fluidic module. Therefore, if a complete valve assembly was to be replaced, some additional work would be required to reposition the threaded joints to enable the new valve to be installed.
However, in this case, only the original valve stem and actuators were to be replaced, leaving the valve body in place. Fortunately, even though the Type 2000 has been updated, the new components are still compatible with the original valve bodies, minimising the downtime required to complete the job.
Pneumatically controlled valves have two ports, inlet and exhaust and in a humid atmosphere damp air can reduce the long-term reliability of the valve. When the valve closes a small amount of ambient air is drawn into the valve to fill the void. In certain circumstances it is advisable to install a silencer on the valve or to draw the air from a cleaner source, such as the inside of a control cabinet. So, when the local Burkert Sales Manager visited the production site he offered this advice on prolonging the service life of the new valves even further than the 10 years offered by the original components.
Having confirmed that the new valve stem and actuator would be a direct replacement for the current components, the job of exchanging them would only take about 15 minutes. If the valve body needed to be replaced this would take considerably longer, especially if the valves had been welded in place.
Simplified process control for reverse osmosis plant
Designing and constructing a new solar power project is a complex operation that
requires a variety of skills and expertise. For one project in Spain, the systems integrator
selected a range of Bürkert products to ensure the cleanliness of the process water in order to
maintain efficiency and productivity.
The solar-thermal plant uses parabolic-through concentrating solar power (CSP)
technology. Parabolic mirrors direct the sun’s rays to a glass collector through which oil flows and gets heated up to around 400ºC. The hot oil is used to turn water into steam which is used to
drive a turbine that turns the generator.
In this case the plant has two 50 MW generators and the water used in the process is
groundwater. All of the impurities need to be removed before it can be used to power the
turbine, otherwise the impurities would gradually build up on the turbine blades leading to
corrosion and possible imbalance of the rotor.
In addition, the purified water is used to clean the mirrors regularly. If this was done with
untreated water the mirrors would suffer from a build-up of contaminants, which would reduce
the efficiency of the energy collection process.
Effective process design
To meet the water quality requirements of the solar plant, a treatment process using
reverse osmosis was proposed to remove the impurities from the water supply. The tier 1
contractor, responsible for the construction of the complete solar installation employed a
systems integrator to deliver the reverse osmosis process. For its part, the systems integrator
approached Bürkert for assistance with the design and implementation of the control system.
The reverse osmosis equipment is designed and manufactured in a skid format that
simplifies the installation process and reduces the amount of time required on site.
Implementing a fluid control system successfully requires a number of objectives to be met.
From the measurement and control of the technical parameters to the visualisation of the
Efficient data display
Bürkert designers worked closely with the systems integrator to create a simplified yet
flexible solution based around the Type 8619 multiCELL controller. One of the key benefits of
the 8619, is the ability to deal with up to 6 channels of data, which reduces the total number of
displays required throughout the installation.
At the time of the design, the 8619 was the only controller capable of displaying flow
measurements as well as analytical data such as conductivity, redox, pH and temperature. The
Type 8619 can be configured to display any combination of these parameters depending on the
needs of the installation.
Furthermore, once the Type 8619 has been programmed, all the settings can be
transferred to a memory card and then uploaded onto any number of similar devices. This
project required two identical skids and this feature reduced the amount of time required for the
setup of the second skid. This has significant benefits for OEMs, minimising any errors
between builds, removing the need for programming technicians for every unit and increasing
Simplifying the procurement process
Bürkert’s wide range of products was an important factor for the integrator, reducing the
number of suppliers and the number of processes required to complete the project.
In all, the project incorporated 12 Type 8619 multiCELL units, as well as 18 Type 8200
probe holders (8200s provide a sealed fixed mount for a range of 120mm analytical probes),
used in this instance to measure pH, oxidation-reduction potential (ORP) and temperature. In
addition, 16 Type 8030 paddle wheel flowmeters, 36 pressure sensors and 18 temperature
sensors were also sourced from Bürkert, along with two pneumatic control cabinets and Type
8640 valve islands.
Ruben Nalda, Area Sales Manager for Bürkert in Spain, explains: “The project integrators
expressed considerable satisfaction with the Bürkert solution, feeling that it offered a very cost
effective and flexible approach, supported by high quality and reliable sensors.”
Once the construction of the reverse osmosis units had been completed, Bürkert offered
to help with the commissioning process to ensure that all of its products were operating
correctly. In fact, the intuitive design of the Type 8619 and the sensors connected to it, allowed
the equipment to be correctly installed and configured by the engineers building the reverse
For OEMs, the intuitive operation of Bürkert’s products means that the manufacturer can
provide its own technical support to customers, without the need for Bürkert assistance. Once a
design has been conceived and implemented, it can provide reliable and cost-effective service
without further intervention, reducing costs and reliance on third parties for ongoing support.
Comparing flowmeters: Coriolis vs surface acoustic wave
Flow measurement of liquids is an essential requirement for the control of many manufacturing processes – since accurate control improves efficiency and guarantees quality. Whilst there are a number of different technologies available, when high accuracy is the requirement the Coriolis flowmeter has so far been the default choice. However, the development of Surface Acoustic Wave (SAW) technology for use in flowmeters has presented a challenger in the market with potentially a host of additional benefits.
For those involved in hygienic applications, such as pharmaceutical, food and beverage industries, the equipment used for product manufacturing, including sensors, must meet stringent hygiene standards whilst also delivering excellent performance. Developing products that can operate reliably in this environment requires considerable dedication and expertise in order to achieve the required standards.
Coriolis flowmeters have until now been regarded as the top-of-the-tree in terms of specification for a flowmeter due to their versatile capabilities for both fluids and gases as well as the ability to measure mass flow. However, the initial cost of such devices can be very high and they do have some constraints.
The design of the Coriolis flowmeter causes a pressure drop across the flowmeter and this can affect the upper limit of the measurement range. The pressure drop increases with viscosity as well as flowrate and the corresponding velocity through the meter.
Additionally, the size and weight of the Coriolis flowmeter requires it to be carefully supported within the process pipework. The space required for Coriolis flowmeters is greater than that required for corresponding designs, with additional pipe supports and installation time required.
The Coriolis flowmeter is suitable for a wide range of applications for both fluid and gas measurement with high levels of accuracy; 0.1% of flow rate which can be improved to 0.05% with special calibration procedures. This design is also capable of bidirectional measurement without the need for inlet or outlet sections in the installation.
However, it is often not a straight-through device and this can have some major drawbacks when it comes to the type of media that can be passed through it, flushing, including product wastage and additional CIP requirements for heat and volume of cleaning process fluid.
Furthermore, in many cases the mass flow measurement may not be required for the application but a Coriolis flowmeter will have been specified purely on the need for accuracy. In such cases, the increased investment in the traditional equipment will be wasted on features that are not required. Now there is an alternative follow measuring device that tackles this and many of the other challenges faced by the Coriolis flowmeter.
In terms of liquid flow measurement then, there is an obvious opening for a device which can deliver a compact, non-contact measurement which is accurate, irrespective of media characteristics, flow direction and flow conditions.
Using Surface Acoustic Wave (SAW) technology, Bürkert has developed a flowmeter in which none of the components are in direct contact with the fluid and which causes no restriction to flow. Furthermore, the internal surface of the tube can be manufactured to the same surface finish as the rest of the pipeline, meaning that in terms of hygiene, cleaning and flow conditions, there is no difference to any other piece of straight pipe within the process.
The main principle of this flow measurement device is based on wave propagation forms similar to seismic waves, which start from an initial point of excitation and spread along the surface of a solid material. FLOWave uses at least four interdigital transducers which are located on the outside of the measuring tube and therefore have no direct contact with the fluid. Each transducer acts both as a transmitter and as a receiver.
The signals that are received are processed by the onboard electronics and software which have also been developed by Bürkert in conjunction with a local university that has been studying SAW technology and its applications. The analysis of all the signals and comparisons based on different criteria such as amplitude, frequency and runtimes, allows evaluation of the quality of the measurement, the existence of gas bubbles or solids as well as the kind of liquid. The result is a flowmeter with an accuracy of up to +/-0.4% and a repeatability of +/-0.2% of measured value with fluid temperatures up to 140°C.
Primarily, the fact that the internal surface of the FLOWave can be manufactured to the same specification as the rest of the production pipeline means that hygienic cleaning processes, including CIP and SIP, can be maintained to the highest standard and at lowers costs. Furthermore, there is no risk of contamination from any components being in contact with the fluid and there is no flow restriction.
FLOWave also solves many of the issues associated with some high-end flowmeters, such as system vibration in the plant, magnetic and electrical effects as well as the conductivity of the liquid – none of these factors have any effect on the accuracy or reliability of the flow measurements, but the SAW technology also has the ability to distinguish between laminar and turbulent flows.
In terms of installation, the process is significantly less complicated when using a FLOWave device as it can be mounted in any orientation and it requires a great deal less space that similar devices using more traditional measurement techniques. The FLOWave can also be specified with or without a display module that can be positioned to suit the final orientation in the process pipework.
Once installed, the FLOWave range offers ongoing benefits including a device status indicator which provides diagnostic status information to the operator, as outlined by NAMUR NE107. In addition, this technology requires considerably less energy to operate; approximately one third of that required by a standard Coriolis flowmeter, which can have a significant impact on running costs and overall total cost of ownership (TCO).
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