Category: Industry Trends

Benefits

• Validation of 360° repeatable cleaning pattern

• Verification of tank cleaning coverage

• Highly accurate detection of the jet sweep and impact

• Improved product quality

Standard design

The Alfa Laval Rotacheck Sensor consists of a stainless steel

IP67-rated casing, sensor, diaphragm, welding adaptor, and

cable for relay connection. As standard ATEX-certified version

is for use in potentially explosive areas. The sensor complies

with Category 1/2 requirements for installation in zones 0/1

and 20/21. The relay complies with Category 2 requirements

for installation in zone 1/21.

Working principle

The sensor of the Alfa Laval Rotacheck Sensor detects the

sweep and impact of fluid jets released as the rotary jet head

performs its cleaning cycle. The system is appropriate

wherever rotary jet heads are employed in cleaning tanks and

where the tank is pressurized during CIP. The signal generated

by the system can be audible, visual or integrated into the

customer’s process control specification.

Based on the geared operation of the cleaning device and

signals recording the impact force from the jets, the sensor

verifies hygienic operation of the rotary jet heads, taking into

account any backpressure in the tanks.

The hygienic Rotacheck sensor is precisely installed to detect

the sweep and impact of fluid jets released as the rotary jet

head performs its cleaning cycle. From the geared operation

of the cleaning device, and by reciving the impact force from

the jets, the sensor provides vertification of hygienic operation.

Any back pressure in the tanks is accounted for.

Benefits

• Durable and cost-effective

• Precision operation

• Long service life

• Easy to operate

Standard design

The Indication unit – inductive consists of steel and

plastic components, seals, contact pins, and cable connection

with socket, screw and cable gland. Easy to mount, this indication

unit does not require any mechanical adjustments and must be

installed between the air-operated actuator and the valve.

Working principle

The Alfa Laval Indication unit – Inductive sensor is an

inductive proximity switch that has non-contact electronic

switching elements. It is activated by an electromagnet device

known as a roller leaf. The standard output signal is always

a digital signal (on/off) indicating the position of the valve.

Introduction

The Alfa Laval Indication unit – Inductive is an electrical feedback

unit that offers cost-effective operation and standard

functionality for automated indication on the inductive side of Alfa

Laval butterfly valves. Straightforward and easy to use, this

indication unit provides information about valve operating status

24/7 while boosting productivity.

This inductive indication unit is compatible with any

programmable logic controller (PLC) with a PNP/NPN interface.

Application

The electrical indication unit is designed with inductive sensors for

use with Alfa Laval butterfly valves in hygienic applications across

the dairy, food, beverage, biotechnology, pharmaceutical and

many other industries.

Introduction

The Alfa Laval ThinkTop® DeviceNetTM is a modular valve control

unit that offers reliable, cost-effective operation and standard

functionality for automated sensing and control of hygienic

valves. ThinkTop DeviceNet provides real-time information about

valve operating status 24/7 while boosting productivity and

securing traceability.

Application

The ThinkTop DeviceNet is designed to control the fluid handling

process in hygienic applications across the dairy, food, beverage,

biotechnology, pharmaceutical and many other industries.

Benefits

• Reliable and accurate valve sensing and control

• Proven and inherently safe design

• Low total cost of ownership

• Watertight design

• Easy to operate

Standard design

The ThinkTop DeviceNet valve sensing and control unit consists of

a proven no-touch, set-and-forget sensor system with light

emitting diodes (LEDs), solenoid valves, and valve control sensor

board for connection to any programmable logic controller (PLC)

system with a DeviceNet interface. It fits on all Alfa Laval hygienic

valves; no adapter is required.

Installation is straightforward. No special expertise or tools are

required. To initiate manual setup, simply press a push

button startup sequence. Or set up without dismantling the

control unit using the optional infrared (IR) keypad for remote

control.

Working principle

The sensor system accurately detects valve stem movement, the

position of the valve at any given time, with an accuracy of

± 0.1mm through the use of microchip sensors. To locate the

current valve position, sensor chips inside the sensor board

calculate the angle between the axial magnetic field produced by

an indication pin mounted on the valve stem.

The solenoid valves receive signals from the PLC system

to activate or deactivate the air-operated valve. It then transmits

feedback signals indicating up to four valve positions and

conditions back to the PLC system.

In the control unit, up to three electric solenoid valves can

physically convert compressed air into mechanical energy to

activate or deactivate the pneumatic valve actuator.

Each control unit fits any Alfa Laval hygienic valve and

provides a tolerance band for valves to prevent product

contamination and failure. This eliminates the need to re-adjust

the sensors and boosts productivity.

LEDs conveniently display all the valve positions, solenoid

activation, setup and local fault indication on the control unit.

Standard design

The ThinkTop Basic Intrinsically Safe valve sensing and control

unit consists of a proven NAMUR feedback sensor system with

light-emitting diodes (LEDs), low voltage solenoid valves, ready

for connection to a electrical barriers and to

any programmable logic controller (PLC) system with a digital

interface. It fits on all Alfa Laval hygienic valves; no adaptor is

required.

Working principle

By an indication pin mounted on the valve stem,

the NAMUR feedback sensors detects valve stem movement, the

position of the valve at any given time, with the adjusted accuracy

of the feedback sensors.

The Alfa Laval ThinkTop Basic Intrinsically Safe is fitted with up to

two solenoid valves that can convert compressed air and the

electrical PLC signal into mechanical energy to activate or

deactivate the pneumatic valve actuator.

Introduction

The Alfa Laval ThinkTop® Basic Intrinsically

Safe is a modular, explosion-safe automated valve control unit

that offers cost-effective operation and standard functionality for

automated sensing and control of hygienic valves. It provides real

time information about valve operating status 24/7 while

boosting productivity.

Application

The ThinkTop Basic Intrinsically Safe is designed to control the

fluid handing process in hygienic applications across the dairy,

food, beverage, biotechnology, pharmaceutical and many

other industries.

Benefits

• Reliable valve sensing and control

• Proven and inherently safe design

• Low total cost of ownership

• Watertight design

• Easy to operate

Introduction

The Alfa Laval ThinkTop V55 is a slimmer, smarter, one-size-fits

all sensing and control unit for diaphragm valves used in the

pharmaceutical, biotech, and next-generation food industries.

Built on the reliable Alfa Laval ThinkTop V-series platform, this

valve control unit is trusted by dairy, food, beverage, and brewery

manufacturers worldwide for its simplified setup, live replacement

and unmatched peace of mind.

Application

ThinkTop V55 is designed for use in the biopharma industries,

dairy, food and beverage.

Benefits

A single, proven diaphragm valve sensing and control unit

• Peace of mind – optimize valve control and increase uptime

• Simplified setup and replacement – save time and money with

fast, intuitive valve configuration and replacement without

production stops

• Compact and flexible – slimmer profile fits into tight spaces,

minimizing installation footprint and maximizing plant

efficiency

• Real-time monitoring and control – choice of digital, ASI, and

Industry 4.0-based IO-Link communication platforms

• Self-diagnostic technology –prevent unplanned downtime by

monitoring valve health and performance

Working principles

The control unit offers a single sensor solution for diaphragm

valves, and it can be fitted with 0 or 1 solenoid valves. ThinkTop

converts the electrical PLC output signals into mechanical energy

to energize, or de-energize, the air-operated valve. Feedback of

valve position is provided using the physical sensor target

mounted on the valve stem.

Installation with Auto Setup or Live Setup is intuitive and fast. To

initiate Auto Setup, simply press the “SELECT” button and then

the “ENTER” button to begin the setup sequence. The ThinkTop

automatically recognizes the type of valve and completes the

programming sequence fast and efficiently.

Alternatively, the ThinkTop can be set up, without dismantling the

control head, using the built-in Live Setup feature for remote

configuration.