Role of integrated hydraulic & pneumatic systems in the automation of food and beverage production

15 January, 2025

While automated cleaning and sanitisation technologies are increasingly common, manual supervision remains an essential part of hygiene management in many food production environments, particularly in smaller facilities. The integration of automation into existing cleaning protocols allows for more precise, consistent, and efficient hygiene practices. However, human intervention may still be necessary, especially during system commissioning or in complex systems where special attention is required.

An emerging trend is the integration of sanitation sensors into hydraulic and pneumatic systems. These sensors enable real-time monitoring of hygiene levels, tracking critical parameters like fluid contamination or air quality. If contamination is detected, operators are immediately alerted, allowing them to take corrective actions swiftly to mitigate any risk to product quality and safety.

Optimising energy efficiency

Energy consumption is a key concern in any industrial operation, and food and beverage manufacturers are no exception. Hydraulic and pneumatic systems, while essential, can be energy-intensive, contributing to high operational costs. Integrated automation technologies help optimise energy usage, ensuring that energy is used more efficiently across production lines.

Variable-speed pumps and air compressors adjust their output based on production demand, reducing energy waste. Instead of operating at full capacity at all times, these components dynamically adjust their performance to match the needs of the production process, ultimately lowering energy consumption. For instance, during quieter periods in production, these systems can scale back their operation to save energy, while during peak times, they can ramp up to meet production demands.

Not all food production facilities are equipped with the latest energy-saving features. Older or smaller facilities may still rely on more conventional hydraulic and pneumatic systems, which could lack advanced energy recovery and variable-speed technologies. However, even these simpler systems benefit from integration into automated processes, as real-time monitoring can help identify inefficiencies and adjust operations accordingly.

Additionally, energy recovery systems can be incorporated into pneumatic circuits, capturing wasted energy from air compression processes and converting it back into usable power for the system. This technology is particularly beneficial in large-scale operations, where air is used extensively for product handling, conveying, or packaging. By reclaiming this wasted energy, manufacturers can significantly lower their operational costs and move towards more sustainable production practices.

Integrated systems also reduce downtime by incorporating predictive maintenance features. Sensors embedded in hydraulic and pneumatic components monitor critical parameters such as pressure, temperature, and fluid levels. Maintenance teams are alerted to potential issues before they result in system failures, allowing maintenance to be carried out during non-production hours. This predictive maintenance approach ensures that systems remain operational and efficient, while also reducing the risk of costly unplanned downtime.

Integrated systems in food and beverage manufacturing

To better understand the practical applications of integrated hydraulic and pneumatic systems, consider the example of a beverage bottling plant that uses a combination of hydraulic lifts, pneumatic conveyors, and automated cleaning systems.

Hydraulic lifts are used to position heavy bottles and pallets at different stages of the production line. These lifts ensure that lifting operations are smooth, precise, and energy-efficient.