T h e M a n u fa c T u r e r s V o i c e

Pneumatic actuators for process control valves in Food & Beverage production
and how to reduce investment & maintenance costs
Why is there a need to discuss actuators for the Food & Beverage segment? The reasons are quite simple - there is a huge demand for those so called hygienic valves and actuators also a lot of money is wasted because people (mainly purchasing) are lacking in knowledge with respect to the application of specific valves. irstly, let us have a look inside a standard food / beverage processing facility. Here we usually find 4 Zones (see Figure 1) which define the exposure of the equipment used in these areas. The most exposed zone is the Food Zone. Equipment in this zone normally has direct contact with food, and all exposed surfaces from which food may drain, drip or splash back must be of stainless steel. The 2nd zone is the Heated Food Zone with similar requirements on the equipment. For these 2 internal Zones there is definitely no way that any material other than stainless steel can be used. These first 2 zones comprise approximately 30% of the food processing facilities. Next if we take a look at the other 2 zones: Zone 3 is the Splash Zone Surfaces outside the food zone subject to routine splash, spillage or other soiling in normal use. Equipment in this zone does not have direct contact with food. So there are no restrictions here regarding materials to be used although the material must be resistant against cleaning detergents and hot water and/or steam which is regularly used. This zone accounts for up to 40% of food processing facilities where stainless steel valves are regularly used as well. Zone 4 Non-Food Zone All exposed surfaces other than food or splash zone. This could be, for instance, the utility services for potable water and so on. Now, having examined the different zones inside the food processing facility and the applications / requirements of each, we can see that the biggest area is the splashing zone with 40% of all valves & actuators. If you have a look inside most of these facilities you will see that, even in this area, we find 99% of all valves & actuators are of the same type and material selection as in zones 1 and 2, food / heated food (see Figure 2) but why is this? The main reason is a lack of knowledge and/or uncertainty about the situation. And this costs the end-user a lot of money. The requirements on the valves are, without any doubt, that they be cavity free and stainless steel as the lines are working with foodstuff. But the actuators are not subject to being in contact with the foodstuff and there will, therefore, be

Figure 2

no contamination from that side. The only requirement is resistance against cleaning detergent and hot steam/water from the cleaning devices. See Figure 3 for an example from this area. So here we see a way of saving money without losing quality and reliability. Far from it! We can even improve the quality regarding performance and lifetime.

How can we achieve this?

Just think about the stainless steel actuators from all these stainless steel manufacturers. These actuators are a combination of linear movement compared with a part-turn action of 90. This requires a special slotted guidance groove and an unusual movement of the sealing on the piston which goes hand in hand with high wear and tear besides the very costly manufacturing and material costs as this combined action needs proper machining in conjunction with a perfect design.
April 2010 1

Figure 1

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T h e M a n u fa c T u r e r s V o i c e Nowadays we have a very reliable design in part-turn-actuators as well as perfect quality in aluminium materials offering the best resistance against any kind of cleaning detergent. In addition to this product quality, these actuators work out at only 1/3rd of the price during a lifetime which is generally 10 times longer compared to full stainless steel pneumatic actuators. Be sure that you go for a Scotch-Yoke actuator (size matters see my article on actuator technology; lifetime of the lever system & no abrasion) and, very importantly, an anodised/ hardened aluminium surface and proper epoxy coated endcaps with encapsulated end-position adjustment. This will avoid insufficient or inappropriate material quality simply ask for washing detergent resistance with the requested pH-value you intend to use for the facility / installation. As an add on you can also get any kind of sensing / positioning equipment ure 3 with the applicable Fig enclosure rate and communication possibility. Lets say, for example, sensor boxes from simple mechanical switches to proximity switches, from AC to DC power supply, enclosure rates up to IP68 and any kind of communication interface from HART protocol to any bus interface. Here too you can state your preferred type and manufacturer and you are not limited to the standard package of the manufacturer of the stainless steel valve / drive combination. Taking care of these small issues will result in less maintenance, longer lifetime and equipment which is in line with the regulations on foodstuff applications.

Meet Gnter xler

Gnter xler is a freelancer to the Process Industry and has a long history within the valve industry. He graduated in Process Engineering and Mechanical Engineering in Stuttgart, Germany, holds a MBA degree in VWA as well as a controlling degree and is a REFA specialist. For more than 25 years, Gnter has worked for several companies in the valve business. He is also a member of the IWA, ISA and VDI German Engineer. Gnter can be contacted under guenteroexler@aol.com

2 April 2010

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