PID (Proportional, Integrating, Differentiating) controllers are crucial for precise process control in various industries. From maintaining stable temperatures to managing pressure, pH, and flow rates. They optimize processes to improve quality, efficiency and productivity and play a key role in a variety of applications. Think manufacturing industry, food and beverage, water and wastewater treatment. In this blog, we share some concrete examples of how JUMO PID controllers provide solutions to industrial challenges.
- Temperature control: PID controllers are often used in processes such as heat treatment, extrusion and injection molding. Maintaining a constant temperature is crucial for product quality.
- Pressure control: in processes such as gas or liquid distribution, these controllers regulate pressure to ensure stable operation.
- Flow control: PID controllers maintain the correct flow rate in processes involving liquids or gases, such as chemical mixtures or in liquid transport systems.
In cryogenic technology, where accurate temperature and pressure control is crucial, the existing control was in need of an update. With JUMO PID control technology, we provided a reliable solution for process optimization.
One of our customers from the cryogenic industry was struggling to maintain stable temperatures and the correct pressure level in a system with liquid nitrogen (-160°C to -271°C). The lid of a container, in which products such as test tubes are stored and cooled with liquid nitrogen, regularly froze solid. It was critical to accurately control both temperature and pressure. This helped prevent freezing of important components, such as the lids of the containers, and ensure operational efficiency.
For precise temperature and pressure control, the JUMO dTRON 308 PID controller was implemented. This advanced controller was coupled with the JUMO TYA201 thyristor, which controls the heater and ensures that the lids do not freeze. A differential pressure sensor (type 404304) was added to perform real-time pressure measurements, crucial for the phase separator.
The PID control allowed the system to react quickly and efficiently to changes, resulting in stable processes and minimal disruptions.
The customer now has a system that operates virtually maintenance-free. The control provides reliable temperature and pressure control. This has resulted in a significant improvement in efficiency, lower maintenance costs and minimal downtime. Our solution has resulted in reliable operation of cryogenic processes, which has significantly improved the production process of this relationship in cryogenic engineering.
PID controller application in cryogenic technology
- Oven temperature control: PID controllers are used in ovens to maintain accurate baking or cooking temperatures.
- Fermentation control: in brewing and fermentation processes, these controllers regulate temperature, pressure and pH to ensure consistent product quality.
- Packaging machines: PID controllers manage the temperature of sealing units on packaging lines, ensuring accurate sealing and filling of packages.
At a large producer of meat products for the Benelux and Europe, the existing steam sterilization system for four autoclaves was recently optimized. With the aim of improving control over the cooking process and increasing efficiency.
Challenge
The customer was using an outdated control system that no longer met their requirements for accuracy and reliability. Moreover, they wanted to keep their existing user interface, JUMO SVS 3000 software, which posed a challenge when integrating the new system.
To meet the customer's request, JUMO provided a custom solution using the JUMO mTRON T automation system equipped with PLC technology and a powerful PID control module. The PID controller optimizes the sterilization process by continuously controlling and adjusting temperature and pressure parameters, ensuring consistency and accuracy in the cooking process.
In addition, the JUMO SVS 3000 software has been reprogrammed to be compatible with the new system. The JUMO mTRON T automation system provides optimized processes, minimizing human intervention. In addition, a new Windows 10 computer was installed for remote access, which increased the customer's flexibility.
The customer benefits from improved process control, a more consistent final product and less downtime thanks to the JUMO mTRON T automation system. Remote access provides additional convenience and operational control, resulting in a more efficient production process.
application of PID conroller in food industry
- pH control: PID controllers regulate the addition of chemicals to maintain desired pH levels in water and wastewater treatment processes.
- Flow and level control: they manage water flow and levels in reservoirs and tanks, ensuring efficient treatment and distribution.
- Filtration systems: PID controllers optimize the operation of filtration systems by controlling pressure and flow rates.
Monitoring water quality in electroplating baths is critical for product consistency and regulatory compliance. Our client wanted to optimize processes to better manage water quality.
With six baths full of chemicals such as sulfuric acid and chromium oxide, accurate monitoring of pH, EC and temperature was essential. In addition, there was a need to measure water flow in one of the baths to better manage water loss and replenishment.
We implemented the JUMO mTRON T automation system with powerful PID controllers crucial for automatic control of the process. Our pH and conductivity sensors provide real-time measurements of the process values, which are processed by the PID controllers. In case of deviations from the process values, the PID controllers immediately send adjustments to dosing and pumps, keeping pH and EC values stable.
A flow meter seamlessly integrated with the PID control was used to monitor water flow in the first bath.This enabled the system to accurately monitor the flow and automatically control the replenishment when consumption increased. Not only did this maintain the chemical balance in the baths, it also ensured that the required resources were used efficiently. The JUMO mTRON T HMI visualizes the process in real-time, allowing the customer to effortlessly monitor and adjust the entire system.
With JUMO PID control technology, the customer has complete control over the process, resulting in improved efficiency and lower costs.
application of PID controller in Water and wastewater treatment
