A polished performance in batch control

09/10/2018 09:44:06
 
 
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ImagesClick Image for 300dpi jpg fileA polished performance in batch controlA polished performance in batch controlA polished performance in batch controlA polished performance in batch controlA polished performance in batch controlA polished performance in batch control

Kemet International is at the forefront of precision lapping and polishing technology, creating diamond polishing compounds, slurries and machinery for a wide range of industrial processes. As part of a process improvement initiative, the company wanted to create a more efficient fluid control system, making the entire manufacturing process more productive.

The initial contact with Burkert came through the need for a replacement flowmeter, and the discussion soon turned to the application itself and additional improvements that could be made. The concept included the addition of batch controllers, fluid control valves and level sensors, all of which would improve productivity and reduce waste.

Richard Bolton, Operations Manager at Kemet International, comments: “This project has been developed using Burkert’s expertise with the aim of improving productivity and efficiency. The final installation has achieved this and also helped us with our company goals of reducing waste and minimising energy usage.”

The first objective was to reduce the time taken to fill a storage tank and to add a control circuit that would automatically stop the pump when the tank was full. By installing a larger capacity pump and new pipework, the filling time was reduced by 75%. The addition of a Type 8110 tuning fork level switch gave the necessary signal to the pump to prevent overfilling.

In conjunction with this, a new batch control system was designed and manufactured by Burkert that would allow several pre-set batch sizes from 450 ml to 25 litres to be produced automatically. The system used a paddlewheel flowmeter and an angle seat control valve directly connected to the electronic control module to provide a simple, inline batch control installation.

A second batch control system of a similar design was also installed but this time the batch sizes were much smaller so the pump and associated pipework were sized accordingly. Both systems incorporated the Type 8025 batch controller, which can accommodate seven batch sizes and has a built-in automated calibration process.

In each case the pumps were connected to the batch control panel to allow them to be directly controlled by the batch process. In this way the pumps only operate when necessary, reducing energy consumption and prolonging the service life of the pump.

The final part of the project was installed for the production of de-ionised water and involved the supply of a new 1200 litre tank, along with a pump and the installation of all the pipework to allow several batching points to be supplied at once via a manual ball valve.

The new pump has an improved delivery capacity and throughput has increased by 70%. It is designed to provide a pressurised supply to four outlets. When demand is low the water is recirculated back to the storage tank via a bypass valve. The installation includes a digital flowmeter, located downstream of the pump, that also acts as a totalizer to record the amount of de-ionised water produced each day.

Richard concludes: “The final installation has delivered exactly the improvements we were specified and were promised, which will certainly improve productivity. The project has run very smoothly and Bürkert will continue to provide on-going field support.”

Image Captions:

Image 1: The new batch control system has improved efficiency and productivity.

Image 2: The Type 8025 batch controller has a built-in automated calibration process.

Image 3: A second system for smaller batches used a similar control process.

Image 4: A Type 8110 tuning fork level switch was used to prevent over-filling.

Image 5: The paddle-wheel flowmeter was used in conjunction with an angle seat valve to control flow.

Image 6: A new 1200 litre tank was installed for the production of de-ionised water.

About BURKERT

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.

The image(s) distributed with this press release may only be used to accompany this copy, and are subject to copyright. Please contact DMA Europa if you wish to license the image for further use.

Editor Contact

DMA Europa Ltd. : Brittany Kennan
Tel: +44 (0)1562 751436 Fax: +44 (0)1562 748315
Web: www.dmaeuropa.com
Email: brittany@dmaeuropa.com

Company Contact

Bürkert Fluid Control Systems : Kirsty Anderson
Tel: +44 (0)1285 648761 Fax: +44 (0)1285 648721
Web: www.burkert.co.uk
Email: kirsty.anderson@burkert.com

 
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