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

15 January, 2025

The food and beverage industry faces numerous challenges, particularly when it comes to balancing production efficiency with stringent hygiene and safety standards. As automation continues to play an increasingly important role in modern food production, integrated hydraulic and pneumatic systems are becoming vital components of production lines. These systems, combined with the integration of digital technologies, not only enhance operational efficiency but also ensure compliance with hygiene regulations, reducing contamination risks and improving food safety standards.

The backbone of automation in food production

As the food and beverage industry increasingly adopts automation, hydraulic and pneumatic systems have become fundamental to achieving the efficiency and precision required in modern production. These systems, particularly when integrated with other technologies such as Internet of Things (IoT) devices, artificial intelligence (AI), and machine learning, create more comprehensive and intelligent automation solutions that enable a more streamlined and error-free production process.

Hydraulic systems, with their capability to handle heavy lifting and force-driven tasks, are invaluable in applications such as lifting large containers or equipment. Pneumatic systems, by contrast, are ideal for faster, lighter operations, such as moving products along the production line or handling packaging tasks. The integration of these systems enables food manufacturers to optimise workflows, reducing the time and labour required for manual tasks while improving both speed and quality of production.

However, while large, highly automated plants benefit from these sophisticated technologies, smaller or more traditional food manufacturers may still operate with simpler hydraulic and pneumatic configurations. These smaller facilities may use basic systems that support fewer automated functions, but even in these cases, the automation and efficiency benefits of these systems are still highly evident. The degree of sophistication and integration will vary based on factors such as facility size, production scale, and available resources.

Ensuring hygiene through integrated automation

Food safety is paramount in the food and beverage industry, and hygiene plays a crucial role in maintaining safe products. Contamination risks in food production are a significant concern, and both hydraulic and pneumatic systems must meet stringent hygiene standards. Increasingly, manufacturers are turning to automated cleaning systems integrated within these technologies to ensure continuous compliance with hygiene protocols without halting production.

For example, integrated systems can automate cleaning cycles for hydraulic lines, pneumatic valves, and conveyors. Food manufacturers can programme these systems to trigger washdowns or sterilisation procedures based on production schedules, ensuring that cleaning happens seamlessly between production runs or after certain quantities of goods are produced. This automated approach not only saves time but also reduces the likelihood of human error during manual cleaning, ensuring consistency in hygiene practices.

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.

Pneumatic conveyors transport bottles through various stages of the production process, including filling, capping, and labelling. Pneumatic systems are particularly beneficial in these contexts due to their speed, cleanliness, and minimal risk of contamination.

Automated cleaning systems are integrated into hydraulic and pneumatic lines, providing automated wash cycles at the end of each production run. This reduces the need for manual cleaning and ensures hygiene standards are consistently met without disrupting production.

In large, highly automated facilities, these systems may also include advanced monitoring technologies, such as IoT-enabled sensors and remote diagnostics, which offer real-time insights into system performance. If pressure anomalies or air quality deviations are detected, alerts can be sent to operators for immediate resolution.

However, this level of automation and integration may not be available in smaller or less sophisticated bottling plants. In these operations, systems may not be as fully integrated, and automation features may be more limited. Even so, smaller facilities still benefit from the integration of hydraulic and pneumatic systems, particularly in terms of energy efficiency, cleaning automation, and basic system monitoring.

Remote monitoring and diagnostics

As the food and beverage industry continues to embrace digitalisation, remote monitoring has become an increasingly important tool in the management of hydraulic and pneumatic systems. In large-scale operations, remote diagnostics and monitoring platforms, often powered by IoT technology, enable operators to track the performance of individual components across multiple production lines.

These systems provide real-time data on parameters such as hydraulic pressure, air flow, and fluid contamination levels, giving maintenance teams and operators immediate insights into system health. This proactive approach to system management allows for swift identification of potential issues and enables manufacturers to take corrective actions before a failure occurs, ensuring uninterrupted production and minimal risk to hygiene standards.

While remote monitoring is widely used in large operations, smaller plants may not yet be equipped with this technology. In these cases, operators rely more heavily on manual forms of monitoring and diagnostics. However, as the cost of IoT-enabled sensors and cloud-based platforms continues to decrease, it is expected that even smaller facilities will increasingly adopt these technologies in the near future.

The future

The integration of hydraulic and pneumatic systems with modern automation technologies represents the future of food and beverage manufacturing. By combining these systems with IoT, AI, and energy-efficient technologies, manufacturers can increase production efficiency, improve hygiene standards, and reduce operational costs. The flexibility of these integrated systems allows them to be tailored to a variety of production scales, from highly automated, large-scale operations to smaller, more traditional food production facilities.

While large-scale food manufacturers are leading the way in adopting the latest digital and energy-saving technologies, smaller plants still benefit significantly from the integration of hydraulic and pneumatic systems into their production lines. Even in these environments, automation, predictive maintenance, and energy management can drive substantial improvements in both efficiency and hygiene.

As technology continues to advance, the role of integrated hydraulic and pneumatic systems in food and beverage production will only expand, further shaping the industry’s ability to meet the growing demand for safe, high-quality food products.