Automated batching systems improve efficiency
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Burkert Fluid Control Systems product story
Edited by the Engineeringtalk editorial team
Mar 17, 2003
A new ten-station batching system designed for Murphy and Son controls and monitors quantities of chemicals and other liquid materials used to produce specialised products for the brewing industry.
Burkert Fluid Control Systems has designed and installed a ten-station batching system for Murphy and Son to control and monitor quantities of chemicals and other liquid materials used to produce specialised products for the brewing industry.
The Nottingham based company was established in 1887and is today one of the brewing industry's leading consulting and manufacturing chemists, producing high quality brewing ingredients and supplements for the production of beer.
Its customers include most of the major breweries and many of the UK's 350 smaller breweries.
Murphy's production is centred on three levels of a former tower brewery building.
Bulk liquid ingredients are stored on both the ground and third floor levels.
The first floor houses the mixing tanks for the ingredients and the second floor accommodates the safe access to the top of four large mixing tanks for sample testing and introduction of powder ingredients.
The manual processing of batches of chemicals that range from100-3000 litres was a full-time job for the operator, which involved filling tanks by opening manually operated valves and continuously monitoring the whole process.
A spokesman for Murphy and Son says the Burkert continuous process control system was designed to improve process efficiency and remove health and safety concerns by reducing the operator's exposure to chemicals.
At the core of the system are the ten batch controllers, one for each of the ten liquid products, mounted in a bespoke cabinet constructed of chemical resistant plastic.
A pneumatic system was installed to allow the flow of materials via actuating valves, which function when the operator enters the volumes required.
This in turn prompts the production of each batch via paddle-wheel, magflow and positive displacement meters.
These meters are matched to the viscosity of the different chemicals and therefore monitor the volumes required.
Magnetically driven pumps have also been integrated with the batching system to increase the volume and accuracy of the materials being dispensed.
The General Manager at Murphy and Son says the new Burkert automated control system, which is located on the second floor of the building, has dramatically improved the efficiency of the production process.
"Where previously the operator had to move between three floors and numerous operating stations to open valves manually and conduct visual checks on tank levels and volumes, he now simply presses a sequence of buttons to control and monitor the whole process from a single station", he says, adding that this has allowed the operator extra time, sometimes "hours", to perform other duties within the work area.
Commenting on the working relationship with Burkert he says the exchange of information and technical support during the design and installation was excellent and concludes by saying.
"We have every confidence in the reliability of the system and the compatibility of Burkert's fluid control components with the materials being processed, which include 65% sulphuric acid solutions".
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