Local manufacturers are increasingly adopting smart pneumatics to modernise operations, reduce unplanned downtime and improve energy efficiency, says fluid control systems manufacturer Bürkert.

Consequently, the company has launched two new products for the South African and broader African market – the valve island Type 8652 AirLINE and the field device Type 8653 AirLINE Field.

These solutions are designed to simplify the setup and maintenance of pneumatic systems and lower the risk of process failure; they can be installed either within control cabinets or directly on the production floor.

The products are geared for Industry 4.0 applications, making them fully compatible with smart factory systems, says Bürkert account manager André Nel.

“These devices are compact, save space and have built-in screens (liquid-crystal displays) that show the status of the valves, detect faults – such as broken wires or pressure issues – and provide custom alerts.”

Bürkert’s intelligent valve systems are gaining traction across various industries, but Nel highlights that every industry presents distinct operational challenges, and the company’s systems have been developed with these requirements in mind.

“Pharmaceutical and biotech industries need very clean and sterile environments. There’s a risk of cross-contamination, and dosing must be very precise. Bürkert provides smart control heads and real-time monitoring systems that meet strict hygiene standards and are approved by health authorities.”

Routine cleaning requirements and concerns over product loss, owing to valve faults, are key operational considerations in the food and beverage sector.

“Bürkert, therefore, supplies hygienic valves that are easy to clean and fast-switching valves to avoid mixing errors. The systems also detect air leaks and recycle air to save energy,” he adds.

In the industrial automation and manufacturing industry, unplanned shutdowns and complex wiring are common problems, Nel notes, adding that Bürkert’s decentralised automation systems simplify wiring, and reduce downtime using predictive diagnostics and maintenance.

The company also offers safe, certified valves with strong sealing and precise control for the demanding applications in the hydrogen and energy sectors, which often involve high-pressure systems and flammable gases, he elaborates.

Preventative Maintenance

One of the primary advantages of Bürkert’s smart valve systems is their supporting preventative maintenance.

The valve systems can connect to industrial networks, such as IO-Link, Profinet and Ethernet, allowing for real-time condition monitoring and diagnostics.

They also integrate with maintenance dashboards, making it easy to track and plan service needs, and enabling users to continuously monitor for faults and issue alerts, adds Nel.

The valve systems can detect valve failures, short circuits, abnormal temperatures or voltage levels, in addition to tracking usage metrics such as switching frequency and power consumption. All this data is fed into the control system to allow for proactive maintenance.

“Bürkert’s systems include built-in counters that track how many times a valve has been used. There are . . . resettable counters for maintenance intervals and permanent counters to track metrics over the valve’s life span. Users can set warning limits for things like temperature or switching frequency. This helps catch issues early.”

The central platform allows for trends analysis and assists users in identifying potential problems before a failure occurs, he adds.

Automation

Nel notes that automation solutions that incorporate Bürkert’s intelligent valve banks boast enhanced uptime and extended maintenance intervals.

Each system’s modular architecture allows for the option of hot-swapping components without disrupting operations and built-in software automatically configures new parts for seamless integration. Using standardised components also simplifies maintenance and spare parts logistics.

There are also clear sustainability benefits associated with these pneumatic systems, with

Bürkert’s offering contributing to environmental goals by integrating energy efficient and waste-reduction features.

“The low-energy valves minimise power consumption by switching to an energy-saving mode after activation, while zero air consumption in standby mode on our smart positioners, further reduces waste. Some valves enhance efficiency by recycling air, optimising resource use. The systems also feature longer-lasting components, decreasing the frequency of replacements and reducing material waste.”

Additionally, the proactive maintenance approach supports operational efficiency and prolongs equipment life, contributing to more sustainable practices overall.

Gaps in Industry

While the uptake of smart pneumatics is increasing among major South African manufacturers, particularly those that operate in the automotive, food and mining sectors, Nel says adoption remains limited among smaller enterprises.

“We have noted that several gaps still exist in the adoption of smart pneumatic systems. Many facilities continue to rely on legacy equipment, such as traditional pneumatic systems, which makes retrofitting costly and complex. Additionally, there is a skills shortage, with many organisations lacking in-house expertise to implement and maintain advanced systems.”

Cost sensitivity is another obstacle. Add-itionally, companies often struggle to integrate smart pneumatics into larger digital control systems or PLCs. Nel says that overcoming these challenges will be key to broader industry adoption.