HEALTH & SAFETY
PRECISION CONTROL
BURKERT
FINDING THE BEST PARTNER FOR
HYGIENIC PROCESS CONTROL PROJECTS
Precision control of fluids and gases is a
task that requires technical knowledge
and experience. Within this area, hygienic
applications, such as those in the
pharmaceutical and biotech industries,
place even higher demands on the
control components and the surrounding
infrastructure. So, when embarking on a
hygienic process control project, finding the
most qualified partner is essential to success.
Ian Webster, Hygienic Processing Field
Segment Manager from Bürkert UK, looks
at the essential attributes that are required
from an engineering supply partner to
deliver a successful installation.
Control technology and component designs
are constantly changing, introducing new
features and benefits, so keeping up with
the latest innovations can be a challenge in
itself. At the same time, applications in the
pharmaceutical and biotech industries often
require an investment in reliability and safety
as much as cutting-edge technology.
DESIGN RESOURCES
Designing, specifying and building hygienic
process control projects requires very
specific expertise and resources; bringing
them together at the earliest opportunity
will pay significant dividends in the long
term.
For example, many process control projects
require a combination of ‘off-the-shelf’
components and bespoke valves or valve
blocks to minimise connections and dead
volumes. All processes will require cleaning
or sterilising procedures that need to be
as efficient as possible to maximise the
productivity of the line.
Using steam or hot wash processes
requires considerable amounts of energy,
so innovative manufacturers have created
products to minimise energy requirements.
By reducing weight and making components
smaller, less energy is needed to achieve the
required temperatures and energy usage is
optimised.
Once the scope and specification of a project
have been finalised, getting into the detail
of how the project will be delivered is where
expertise really pays off. While it might
appear straightforward to just order all the
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PECM Issue 37
The design of process control infrastructure for hygienic applications requires
considerable expertise.
valves, control heads, sensors and controllers
from the incumbent suppliers, it is often
worthwhile to challenge this status quo.
REDUCING LEADTIME
One of the sticking points for these projects is
the lead-time for the more complex or larger
valves. In some cases, this factor alone can
determine the duration of the project, or at
least the earliest start time. By working more
closely with the manufacturer, it is possible to
establish these milestones earlier and work to
minimise their impact.
The next aspect to look at is the dispersal
of the purchase orders and what resources
are required to design, manufacture, install
and commission the project. This applies not
only to the external suppliers but also to the
amount of in-house support that is required
to administrate and manage the project.
By reducing the number of external suppliers,
the level of internal resources required
can also be minimised. By working with a
manufacturer that offers a comprehensive
range of products as well as the engineering
expertise to develop bespoke products
quickly, it is possible to install a fully
integrated project in a shorter lead time.
This approach also delivers additional
benefits, in that all the products work
together seamlessly, use the same
communications protocols and should be
delivered in a coordinated manner.
OPTIMISED PRODUCTIVITY
Looking at alternative configurations will
often bring new insights to design and
the layout of process control systems. For
example, depending on the application,
changing from a centralised control
infrastructure using valve islands to a
decentralised system, can reduce installation
time and offer more flexibility in the design.
Furthermore, new partnerships can reveal
innovative products and technologies that
improve efficiency or increase productivity.
Without exploring the alternatives, businesses
risk closing themselves off from exciting new
developments. The alternative simply trusting
in the ‘tried-and-tested’ process can lead to a
stagnation of ideas.
At Bürkert, specialist designers and engineers
continually strive to meet the challenges
of hygienic process automation, using the
latest technology to deliver state-of-the-art
solutions that work in harmony with existing
facilities. Extensive industry knowledge and
the ability to deliver bespoke components for
any scale of project, sets the standard for the
industry.
www.burkert.co.uk