Maintaining the edge over competitors is never easy. Operations must be continually improved, and production capabilities optimised. At Alfa Laval we understand these demands, and the requirement that your equipment performs at its best throughout its lifetime. We help keep you competitive by minimizing costs and maximising the return on your equipment investment. Our global service network and 360° Service Portfolio support your operations at all times, stopping problems before they occur.
Correct maintenance is crucial
Extending the performance of your equipment relies on the correct maintenance procedures being observed. Magnus Christersson, Division Manager at Service Nordic, Alfa Laval explains, “performing regular maintenance on your equipment is key to reducing costs and securing uptime in production.” Alfa Laval’s global service network is driven by customer needs, dedicated to securing production uptime, being readily available, providing quality service and optimization to ensure your peace of mind.
Proper service, performed at the right time, saves you money and prevents unplanned interruptions. The experts of our network have the skills, experience and procedures to spot problems before they occur.
Wherever your operations are, our network is there. You have easy access to expert support from responsive people who care about your equipment and process performance. The same is true when it comes to parts. Alfa Laval’s dedicated team gets the right parts to where you need them – in the right number and in as little time as possible. Christersson continues, “we deliver on the availability of our field service engineers and technical salespeople. We understand your need for a speedy response when it comes to your production and try to respond to all requests within one day.”
To safeguard the quality of your operations, only genuine Alfa Laval spare parts are used, which are designed for your equipment and manufactured for safe, reliable performance. “Our quality relates to anything from spare parts, to the quality of our field service engineers, who are not only fully qualified, but are part of our global network within Alfa Laval, serving your needs wherever you are,” says Christersson.
The challenges you face may change over time. New media and capacities appear, as do changes in regulations and other business drivers. Solutions are available to adapt your equipment based on the latest technology and Alfa Laval experience worldwide. By listening closely to your needs, the experts of our global network provide the right solutions for you.
Alfa Laval 360° Service Portfolio
We partner with you all the way – from start-up, maintenance and support, to improvements and monitoring services. We have all the parts and services to ensure your equipment performs to the level it was designed to – both now and in the future.
We bring your equipment into operation smoothly and safely, while respecting global guidelines. We ensure your equipment delivers as it is meant to from the get-go.
With proper maintenance at the right time, you can achieve higher performance and lower operating costs while maximizing your equipment’s lifetime.
Assistance is always on hand. Many issues can be solved directly over the phone, and experienced troubleshooting specialists can be dispatched to your site when needed.
Stopping problems before they occur saves time and money. Inspections and audits – or even continuous monitoring – can keep you informed of any performance changes.
Performance can be taken to the next level to better match your evolving needs. We can improve your equipment, letting you take advantage of the latest technical developments.
Preventive maintenance – prevent problems before they occur
By servicing your equipment only when necessary, you can ensure operational reliability and maintain performance. Preventive Maintenance reduces unplanned stops, increases equipment lifetime and reduces workplace accidents. It also enables you to make the best use of resources and reduce spare parts stock.
Preventive maintenance is performed as a stand-alone service when your equipment has been in operation for a certain number of hours, and at a fixed interval to avoid unplanned stops. The service can also be part of a Performance Agreement. Our experts analyze your operating conditions, determine accurate maintenance intervals based on various factors, including type of application as well as the usage and condition of the equipment, supply genuine spare parts, and perform maintenance on board, on site or in one of the Alfa Laval Service Centres located close to you.
Alfa Laval is a leading global provider of specialized products and engineering solutions based on its key technologies of heat transfer, separation and fluid handling.
The company’s equipment, systems and services are dedicated to assisting customers in optimizing the performance of their processes. The solutions help them to heat, cool, separate and transport products in industries that produce food and beverages, chemicals and petrochemicals, pharmaceuticals, starch, sugar and ethanol.
Alfa Laval’s products are also used in power plants, aboard ships, oil and gas exploration, in the mechanical engineering industry, in the mining industry and for wastewater treatment, as well as for comfort climate and refrigeration applications.
Alfa Laval’s worldwide organization works closely with customers in nearly 100 countries to help them stay ahead in the global arena. Alfa Laval is listed on Nasdaq OMX, and, in 2018, posted annual sales of about SEK 40.7 billion (approx. 4.0 billion Euros). The company has about 17,200 employees.
Butterfly valves… the ideal valve for sugar!
Sugar manufacturing poses a challenge to valve makers. The characteristics of the material to be handled, fluctuating pressures and high temperatures and viscosities present great demands to valve engineering.
Due to the competitive market situation in the world of sugar, nowadays the responsible factory managers of sugar factories are required to pay increasing attention to all available options of rationalization and cost savings. The availability of all system components has been especially scrutinized. Thinking in terms of life cycle cost and cost of ownership is gaining significance. While in the past many system components such as pumps and valves were simply replaced after the campaign, they now require much higher durability.
According to the sugar factory managers a high reliability and long service life, service friendliness and functional reliability are just as much on the priority list as the potential for automation. However, the most important element during the campaign is service around the clock. Most of the times the sugar factories expect service by mobile phone from the supplier any time of the day and night. Of course, all this also applies to the numerous valves and fittings. Valves are used everywhere in sugar production: From juice production to juice purification, juice concentration and sugar crystallization. While a typical production facility (referring to a 10,000-ton factory) has “only” 200 to 220 pumps, valves (typically: butterfly valves) can be found much more often. A beet processing factory of 13,000 tons/ day is estimated to utilize approximately 3,000 installed valves. With roughly 1,000 valves in the beet end (that is one third of the total number) most valves are used here; large quantities can also be found in the evaporation crystallizers in the sugar house, in the power station and especially in waste water treatment. When the factory is running sugar juices at the crystallization point, even the smallest temperature variations or thermal bridges are enough to crystallize the medium. A regular valve would clog immediately. Butterfly valves are not as sensitive and can be heated more easily.” Butterfly valves therefore cover the largest application scope of most media handled in the sugar factory.
Section of a soft sealing flucon shut-off valve, series, series 23/24. The fact that the elastomer (EPDM-H) is vulcanized onto the support ring can be clearly seen.The high temperatures and especially the vacuum are extremely critical for the valves used here.
The soft sealing flucon series 23/24 butterfly valve with replaceable EPDMH liners (resistant up to 130°C) by Airpower, showing best results in many evaporation crystallizers worldwide, provides the solution. With the flucon butterfly valves the elastomer is permanently vulcanized on the interchangeable support ring thereby ensuring a vacuum tight housing liner; the elastomer cannot be deformed caused by the vacuum. These valves are therefore particularly suitable for vacuum processes. Combined with the robust twintorque pneumatic actuators on/off or control valves offer the perfect solution for most critical applications in the sugar factories.
New control heads extend the life of process valves
Investing in high-quality process control valves have several operational advantages, including an extended service life. However, when just the valve actuators reach the end of their service life, the options can be limited, especially when the OEM parts are obsolete.
Fortunately for a UK based malt processer Bürkert has been able to provide a cost-effective retrofit solution for two hundred third-party valves, upgrading them with Bürkert Type 8691 control heads to keep the full complement operational for years to come.
The food and beverage industry uses process control valves extensively to manage the flow of liquids and gases throughout the manufacturing process. As such, their reliability is essential to the continued operation of the food manufacturing process: keeping sufficient spare parts available is therefore an important task.
However, as equipment ages, the original equipment manufacturer (OEM) may no longer support the product. At this point, maintenance managers can be left with just their own stock of spare parts, which will, inevitably, run out at some point.
In this case, the food manufacturer took the opportunity to investigate the alternatives, starting with replacing the control valves completely. With over 200 process control valves affected, replacement would be a substantial investment and the payback period would have been longer than desired.
At the same time, Bürkert, as an existing supplier to the company, was invited to offer a solution. Craig Kerr, Sales Manager at Bürkert, explains: “We were provided with a spare control valve from the production line and asked to deliver a proposal that would resolve the issue of ageing controls, while retaining the value in the valve body.”
As a major manufacturer of process control valves, Burkert could have offered a complete replacement valve, but having assessed the condition of the valve body decided that just the control head needed attention. The obsolete pneumatic actuator could be replaced with Bürkert’s Type 8691 control head with the simple addition of an adapting bracket to attach it to the legacy valves.
Plug & Play
Craig continues: “The manufacturing process operates a decentralised control system using ASI, with the valves either open or closed. Bürkert’s suggested solution would provide a simple, plug-and-play control head that would easily attach to the control valve body.”
In all, it would take less than an hour to replace each control head. This includes assigning an address for the PLC and using the tuning function where the operator presses the buttons to open and close the valve. The integrated valve position sensor registers these points and stores them to ensure reliable valve operation.
The Type 8691 is ideally suited to the food and beverage industry; being constructed from stainless steel, with excellent ingress protection ratings, it is easy to clean and has excellent chemical resistance properties. In addition, it is equipped with bright, coloured LED status indicators that show the position of the valve at a glance. Craig concludes: “The customer had the first unit on trial for a short period before ordering a further one hundred units. These were all installed and commissioned by the customer and one year on, they are all continuing to function reliably. This solution has been very cost-effective, saving thousands in process hardware and replacement costs by allowing the customer to retain the original valves and minimise any potential downtime from the upgrade.
Burkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2,500 people and has a comprehensive network of branches in 36 countries world-wide.
New hydraulic tipping valve will increase productivity in tipping operations
Edbro is introducing a new hydraulic valve for tipping trucks, which will allow faster lowering than was previously possible. This will lead to a quicker turnaround time of tipping operations and therefore increased productivity.
Edbro, a member of the JOST World since 2012, is a highly regarded leader in the manufacture of on-vehicle hydraulics systems. It maintains its position at the forefront of the tipping market by always working to increase payloads, reduce tipping times and provide “fit and forget” solutions that require little or no servicing over their entire working life.
Replacing the incumbent CT range of valves, the UT valve is completely interchangeable with the older part. This ensures that vehicle operators can continue to maintain their existing hydraulic kits without any issue. Like its predecessor, the UT valve increases safety during lowering and offers lightweight performance.
The UT range introduces an optimised internal oil flow which reduces flow restrictions. As a result, the maximum lowering speed of the valve has been increased, reducing the time taken per tipping cycle. While this will be appreciated by all users, it will be particularly useful in quarrying and other operations where multiple tippings are made each day – the time savings on each cycle adding up so that the trucks can complete more runs per shift.
Danny Broomfield, Sales Director for UK & Ireland, comments: “The Edbro slogan is Lighter, Faster, Stronger. We achieve these goals by maximising the performance capabilities of every components found in our systems. The introduction of the UT valve will play its part in making sure our customers have the fastest and safest tippers on the market.”
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