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 this technology can provide.
Today’s consumer market and food safety regulations demand greater process visibility, making networked control 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 such a solution with its SideCONTROL range of digital positioners and process controllers for valves. This series helps with the transition to digital control, making it efficient and simple.
An Australian food and beverage manufacturer recently took advantage of Burkert’s SideCONTROL devices to update its existing Sampson valves to digital control via IO-Link. Burkert supplied Type 8791 SideCONTROL positioners for nine existing valves and Type 8635 positioners for four valves in a Zone 2 hazardous area, which provided the full PID control loop function in conjunction with a temperature sensor – therefore not requiring a separate PLC.
Burkert’s SideControl positioners are suitable for food and beverage applications because they can be used in a wet environment where operators need remote access. 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 – there is zero air consumption in controlled states.
The SideCONTROL digital positioners offer simple operation via a graphical display and keypad or via 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 digital positioners, food processors can modernise their control systems cost-effectively while preserving existing valve infrastructure.