Hygienic sanitary process valves

Hydract double seat Mixproof Control valve. single seat valve, divert valve, modulating valve, regulation valve. EHEDG.

CONTROL BY WATER

Take control by water – due to the incompressibility of water the Hydract process valve is unaffected by pressure transients – increasing your Overall Equipment Effectiveness and minimizing your maintenance.

Hydract process valves. Single seat, double seat mixproof, divert valves. mudulating valve, regulation valve, control valve, mixproof valve, EHEDG valve,

SUSTAINABLE
BEVERAGE
THE EASY WAY

Sustainable goals in a consumer-driven market challenge the beverage industry. Scarce water resources may force e.g. breweries to move location - or to rethink who, where, and how. With water-controlled actuators, the industry can achieve more than 90% reduction in energy consumption, compared to traditional pneumatic actuators.

This actively reduces both your carbon footprint and drastically decreases the need for harmful cleaning chemicals. Not only will you exceed the standards of sustainability, you will be brewing a better world. Using fewer resources will make your business stronger, more sustainable, and more profitable.

HYDRACT engineered by heart

Dive into our story, what we do and how we came about.

The video opens in YouTube and has Danish, English and Spanish subtitles.

DISCOVER
THE BREWERY
OF TOMORROW

How hydraulic process valves are
(R)evolutionizing Carlsberg

Brewing a game-changer at Carlsberg Fredericia.

Over the past 13 years, Carlsberg has been closely involved in the development and testing of the HYDRACT valve, and since 2016, Carlsberg has implemented more than 600 HYDRACT valves in production at the company's brewery in Fredericia, Denmark.

The development started in 2008 as an energy-saving project - powered by hydraulics. The patented process valve technology reduces the electrical power consumption for operating valves by more than 90%, and because hydrualic fluid, unlike air, is incompressible, HYDRACT's hydraulic process valves provide an unprecedented level of precision and control because the valve is not affected by pressure surges in the process line. This means that unintentional mixing of liquids is not possible, for the benefit of reducing waste and increasing food safety.

The technology and valve further evolved from being the sustainable alternative to ordinary pneumatic valves to also enabling high-precision inline mixing and blending of High-Gravity-Beer (HGB) and late product differentiation.

"The tests of the HYDRACT valve have exceeded our expectations. The precision and reliability achieved with HYDRACT process valves as an alternative to compressed air enable a completely new approach to efficient and sustainable beer production. It fundamentally changes the way we can produce beer in the future," says Anders Kokholm, brewery director at Carlsberg Supply Company Denmark.

For a brewery like Carlsberg, this means that instead of brewing and storing beer that is ready for bottling, the brewer can now brew and store only a few basic types of beer with special taste and a high alcohol content, High-Gravity-Beer (HGB).

Hydract mixproof regulation valves for CIP at Carlsberg

Hydract mixproof modulating valves being installed in valveskid for Carlsberg

By mixing these special types of beer and diluting them with deaereted water in a continuous process on the way to the bottling line, HYDRACT process valves creates the opportunity to mix beers On-Demand and Just-In-Time.

The advantage for the brewery is that it becomes possible to only brew and storefull batches of beer with an alcohol percentage that is higher than the final beer. This makes it possible to get optimal utilization of both brewing and storage capacity, which optimizes operating costs and ROI.

In relation to the growing demand in the market for more and more new products, it will be possible to reduce the lead time on a finished beer from weeks to hours. The company is quickly realizing the benefits of changing its setup. “The process is very unique,” says Anders Kokholm. “and you cannot find a valve controlled like this one in the market today.”

The new inline mixing project not only achieves a significant energy saving of more than 99% for the valves but also generates less waste and consumes less water while reducing chemical use and cleaning significantly. Because Carlsberg will be able to brew bigger batches of the same HGB there will be fewer bright beer batches per year – hence less cleaning and a higher filling degree of the BBT.

The way inline mixing is done at Carlsberg, we significantly increase the capacity of the BBT bottleneck in the brewery, whilst lowering the unit cost of producing beer. The system is fully automated using advanced valve, measurement, and software technologies controlling key parameters, such as alcohol, CO2, and colour in real-time, producing final products within specifications and maximizing line utilization, from the smallest batch to the highest speed and capacity available in the industry, avoiding the need for mixing tanks and systems.

Power

Precision

Hydract process valves. Single seat, double seat mixproof, divert valves. All valves are regulating valves and more reliable

”With the valves from HYDRACT, Carlsberg’s production becomes faster and more efficient. Our production becomes easier and cheaper. We achieve better utilization of the raw materials as well as a much more flexible production with increased process reliability. It is crucial for Carlsberg to be better and more competitive than our competitors. It opens so many opportunities and creates such a good economy that it would be wrong to do otherwise."

Peter Rasmussen
Senior process manager. Carlsberg Denmark

Hydract process valves. Single seat, double seat mixproof, divert valves. All valves are regulating valves

"If you want to list all the benefits of using Hydract's valves, then it will be a very long list. The fact that it can stay closed and regulate precisely gives us at Carlsberg the process advantage that we can make a very late product differentiation. We can cut down on our inventories to achieve higher efficiency at the bottling plant and we can produce On-Demand and Just-In-Time while reducing our waste. It will pay off – big time!"

anders kokholm
brewing and quality director Carlsberg denmark

ADVANTAGES

late product differentiation
faster reaction to market
better line utilization
reduce UNDER- OR OVER-PRODUCTION
avoid UNINTENTIONAL MIXING OF FLUIDS
PREDICTIVE MAINTENANCE
OPERATIONAL FLEXIBILITY

REDUCED VARIABLE COSTS
BI-DIRECTIONAL FLOW
ON-DEMAND / JUST IN TIME PRODUCTION
eliminate water hammers
REDUCED CLEANING, CHEMICALS, AND WATER
FULL DIGITAL CONTROl
Higher overall equipment efficiency

DISCOVER THE HYDRACT Valve

HYDRACT is a valve manufacturer of sanitary process valves for the food and beverage industry, including breweries, alcoholic beverages, non-alcoholic beverages, soft drink and juice production, dairy processing, chemical processing, pharmaceutical, liquid foods and other liquid processing industries.

Our comprehensive range of products includes single seat valves, double seat valves, double seat mixproof valves, divert valves, single seat divert valves, double seat mixproof divert valves, Single seat control valves, double seat control valves, and the HYDRACT mixproof control valve, all manufactured to the highest standards of quality and precision.

Please have alook at our valve catalogue.

We understand that each industry has unique needs, and that's why we offer custom solutions to meet your specific requirements.

At HYDRACT, we're committed to sustainability and energy efficiency, which is why our valves are designed to reduce energy consumption and minimize waste. Our cutting-edge valve technology and unparalleled valve regulating precision mean you can rely on us to optimize your processes and improve product quality.

It also means that you can optimize your production processes, and actively let the valve be an active part of your process. We are dedicated to producing the highest quality process valves for a wide range of single seat valves, double seat valves, double seat mixproof valves, divert valves, single seat divert valves, double seat mixproof divert valves, Single seat control valves, double seat control valves, and the HYDRACT mixproof control valves for processing.

HYDRACT Single seat valve:
The Hydract single seat valve housing is designed incorporation with hygienic design specialists to offer a great hygienic and cleanable valve houses for the industry. The design of the valve house creates optimal conditions in terms of cleanability and flow. It is designed to deliver high performance every time, everyday!

The single seat valve houses are clamped together with the actuator to ensure fast and easy assembly of the total valve system. The flow direction is bi-directional, meaning that the flow can be both upstream and downstream using the same single seat valve.

Seat Calibration and lifetime – The seat seal compressioncan be adjusted by connecting the actuator to a tablet (Hydract app). This ensures the seal can be adjusted during it's lifetime and ensure the correct expansion when exposed to heat which aids in increasing lifetime of the seal.

Flow conditions – The reduced pressure drops inherent with this design, when compared to typical ON/OFF valves, is used to gain more control over the same stroke, thus giving more stability.

HYDRACT Double seat mixproof valve:
Our double seat mixproof valve is bi-directional, meaning the flow can be both upstream and downstream. The double seat mixproof valve internals seal off the two pipelines to avoid any unintentional mixing of fluids. If seal leakage should occur, the leaking fluid will travel through the leakage chamber, creating a visible leak indication .Our double seat mixproof valve housing is designed incooperation with hygienic design specialists to offer a range of great hygienic and cleanable valve houses for various industries. Our design creates optimal conditions in terms of cleanability and flow to ensure our double seat mixproof valves deliver high performance every time.

Our double seat mixproof valve's conical shape of the lower seat allows for optimal flow when opening, closing or using the double seat mixproof valve for regulation.

The reduced pressure drops inherent with this design, when compared to typical ON/OFF double seat mixproof valves, provide more control over the same stroke, giving more stability, especially when used in regulation operation. The shape of the flow controlling surface can be engineered to meet the needs of the process, such as quick opening or equal percentage. Our double seat mixproof valve is particularly well-suited for use in a variety of industries including breweries, soft drink and juice production, dairy, and other liquid processing applications.

We are committed to providing our customers with outstanding products and services that meet their specific needs.

HYDRACT Single seat divert valve:
The HYDRACT single seat divert valve is a type of valve that is used to divert or redirect the flow of fluid in a piping system. It is designed to selectively control the flow of fluid through different channels or paths, allowing for greater control and flexibility in a variety of industrial applications. Divert valves can be found in a range of configurations, including two-way, three-way, and four-way valves. Two-way divert valves are typically used to switch flow between two different pipelines or outlets, while three-way divert valves and four-way divert valves are used to switch flow between three or four different pipelines or outlets.

Divert valves are commonly used in applications such as food and beverage production. They can be used to divert or redirect the flow of fluids to different processes or equipment, enabling greater control and flexibility in these processes.

The HYDRACT single seat divert valve comes as both single seat divert valve double chamber and single seat divert valve triple chamber.

HYDRACT Double seat mixproof divert valve:
The Hydract double seat Mixproof divert valve housing is designed in corporation with hygienic design specialists to offer a great hygienic and cleanable valve houses for the industry. The design of the double seat Mixproof valve house creates optimal conditions in terms of cleanability and flow.It is designed to deliver high performance every time, everyday! The double seat Mixproof divert valve is used for diverting flow from an inlet to one or more outlets in the beverage industry. This is an important aspect for flow control and circuits or merging streams from different lines, where the 2 lines must be separated from each other with mixproof function.

Flow direction – the flow is bi-directional (flow can beboth upstream and downstream) Mixproof safety – the double seat Mixproof valve internals seal off the two pipelines to avoid any unintentional mixing of fluids. If seal leakage should occur, the leaking fluid will travel through the leakage chamber instead and thereby create a visible leak indication.

Seals - The available seal materials are EPDM, HNBR or FKM. Reciprocating shaft seals use PTFE as the contact material to extend lifetime.

Seat Calibration and lifetime – The upper seat seal compression can be adjusted by connecting the actuator to a tablet (Hydractapp). This ensures the seal can be adjusted during it's lifetime and ensure the correct expansion when exposed to heat which aids in increasing lifetime of the seal.

Flow conditions – the conical shape of the lower seat allows for optimal flow when opening, closing or using the double seat Mixproof valve for regulation. The reduced pressure drops inherent with this design, when compared to typical ON/OFF valves, is used to gain more control over the same stroke, thus giving more stability, especially when used in regulation operation. The shape of the flow controlling surface can be engineered to meet the need of the process, i.e., quick opening, equal percentage etc.

HYDRACT Control valve:
The Hydract control valve is a high-performance control valve designed for precise control of fluid flow in industrial applications. It is engineered to provide exceptional accuracy and reliability, ensuring that your processes run at peak efficiency. Whether you are controlling the flow of chemicals in a chemical processing plant or dosing water into beer in a brewery, or blending soft drinks, precision is essential. With Hydract valves, you can be confident that you are getting the precision and control you need to ensure that your processes run smoothly and efficiently.

So why settle for anything less?

Contact us today to learn more about Hydract valves and how they can improve the performance of your processes. One of the key features of the Hydract control valve is its advanced actuation system. The valve's actuator is designed to provide high-resolution movement, enabling precise control of flow rates in your process. The HYDRACT control valves, comes as single seat valve control valve, double seat control valve, double seat mixproof control valve, single seat divert control valve, double seat mixproof divert control valve.

This level of precision allows you to maintain tight control over your processes, reducing waste and improving product quality. The Hydract control valve also features an advanced position feedback system, which provides real-time feedback on the valve's position. This enables the valve to respond quickly and accurately to changes in process conditions, ensuring that your processes remain stable and consistent. The Hydract control valve is suitable for use in a wide range of industries, such as soft drink, dairy, breweries, chemical processing, and any liquid processing.

It is available in arange of sizes and pressure ratings, making it suitable for both small and large-scale applications.

HYDRACT Seal materials:
We offer a range of seal materials including EPDM, HNBR, orFKM. Our reciprocating shaft seals use PTFE as the contact material to extend the lifetime of the seal. The upper seat seal compression can be adjusted by connecting the actuator to a tablet using our Hydract app. This ensures the seal can be adjusted during its lifetime and ensure the correct expansion when exposed to heat, thereby increasing the lifetime of the seal.

HYDRACT Actuator:
The Hydract actuator has tremendous force of up to 12.500 N and it is hydraulically locked – eliminating the risk of unintentional mixing of fluids. Due to the precise control and power the Actuator can position the valve piston by 3/100 mm. As the fluid is incompressible it grants better mechanical work.

It simply uses the energy better.

The actuator will by default open and close the valve slowly and ramp-up to full velocity to reduce the risk of creating pressure transients (waterhammers). The HYDRACT actuator reduces the electrical power consumption by more than 99 % for valve actuation.

HYDRACT Precision:
When it comes to controlling fluid flow in industrial applications, precision is key. That's why Hydract valves are engineered to deliver exceptional accuracy and control, ensuring that your processes run at peak efficiency. The control valve is extremely precise and has an accuracy of 0,03 mm. At the heart of the Hydract valve's precision is its advanced actuation system. The valve's actuator is designed to provide high-resolution movement, enabling precise control of flow rates. This level of precision allows you to maintain tight control over your processes, reducing waste and improving product quality.

In addition to its advanced actuation system, the Hydract valve also features an advanced position feedback system. This system provides real-time feedback on the valve's position, enabling the valve to respond quickly and accurately to changes in process conditions. With this level of feedback and control, you can be confident that your processes are running at optimal efficiency.

HYDRACT Valve house design:
We take pride in designing and manufacturing valves that are reliable, sustainable, and precise. Our team of experts have years of experience and are committed to delivering high-performance valves that meet the needs of our customers.

The Hydract valve housing is designed in cooperation with hygienic design specialists to offer a great hygienic and cleanable valve houses for the industry. The design of the valve house creates optimal conditions in terms of cleanability and flow. It is designed to deliver high performance every time, everyday! The valve is designed to be a modular and versatile setup that can be combined crosswise in size.

The shape of the valve house internal is elliptical, which is the optimal combination of globe valve and cylindric valve shape. The elliptical valve shape creates higher flow velocity and thereby minimises the areas with low wall shear stress – thus resulting in faster and more optimal cleaning properties of the valve, flow proportion, and hygiene. By using an elliptical shape, the design becomes more compact thus minimising the installation space needed for valves.

At HYDRACT, our goal is to help our customers achieve their business objectives by providing them with the best process valves on the market. Whether you're looking for a single seat valve, double seat valve, double seat mixproof valve, single seat divert valve, double seat mixproof divert valve or our innovative mixproof control valve, our team of experts is here to help you find the perfect solution for your specific needs.

Contact us today to learn more about how HYDRACT can help you optimize your process and achieve your goals.