HOW A SMART POSITIONER DRIVES EFFICIENCY AND SUSTAINABILITY IN THE PROCESS INDUSTRY.

Sustainability has long been a central aspect of industrial process control. Efficient resource utilization not only deter­mines a company’s environmental footprint but also its economic competitiveness. One of the most crucial factors in this regard is compressed air consumption – compressed air remains one of the most expensive energy sources in in­dustry. The electro-pneumatic positioner EP3 [Fig. 1] by EBRO ARMATUREN sets new standards in this area. It enables precise valve control while minimizing compressed air consumption.

Compressed air is indispensable across many industrial sectors, yet its generation is energy-intensive and expensive. Studies show that up to 10 % of total industrial energy costs are attributed to compressed air. Additio­nally, leaks and inefficient systems lead to significant losses.

Rising energy costs and an increas­ing focus on sustainability are making energy efficiency a priority in the pro­cess industry. Control valves, often seen merely as regulatory components, play a key role – not only in process optimi­zation but also in cost savings and con­dition monitoring.

Smart Compressed Air Manage­ment: A Key to more sustainability

Future-oriented systems would be those capable of precise positioning, minimiz­ing compressed air consumption in idle mode – or even reducing it to zero – to achieve sustainable cost savings. Equally desirable would be reliable IO-Link inte­gration, enabling seamless communica­tion within modern industrial networks and supporting predictive maintenance through automated processes. Science fiction? Far from it – the technology already exists.

Substantial cost savings – already achievable today, with four-digit reductions per plant

It’s obvious: The deliberate combination of modern technology, smart diagnos­tics, and a strong focus on efficiency makes control valves a key technolo­gy in the industrial sector – especially when, like the electro-pneumatic posi­tioner EP3 from EBRO ARMATUREN [Fig. 2], they offer innovative solutions to meet many of these demands. Three key advantages include:

• SMART – Intelligent control algo­rithm with self-optimization: Valve behavior changes over its lifecycle. The EP3 detects these changes and continuously optimizes its control algorithm to prevent overtravel.
• Robust – Minimizing unnecessary pneumatic connections: Conventi­onal systems require separate pneu­matic tubing between the actuator and the valve. The EP3 is mounted directly onto the actuator, significant­ly reducing leakage-prone pneumatic connections.
• Efficient – Zero air consumpti­on in steady state: Conventio­nal systems continuously consume air even when idle. In contrast, the EP3 completely shuts off airflow once the target position is reached.

In a typical chemical plant with hundreds of positioners, using the EP3 can save several thousand cubic meters of com­pressed air per year. At an average cost of € 0.06 per cubic meter, this translates into annual savings in the four-figure range – per plant.

Precision and resource efficiency in industrial processes

Precise valve positioning is crucial for the energy efficiency of industrial oper­ations. In many applications – from food production and water treatment to the pharmaceutical industry – the precision of valve control directly impacts both prod­uct quality and overall cost-effectiveness.

Thanks to its advanced position control system, the EP3 ensures:

• Precise positioning: Minimizes mate­rial losses through precise regulation.
• Avoidance of energy loss: Prevents unnecessary overflow and reduces leakage-related losses.
• Automated adaption to process requirements: Enables continuo­us monitoring and optimization of compressed air usage.

A practical example from the water treatment industry clearly illustrates the benefit:

In this environment, precise chemi­cal dosing is essential to ensure both water quality and process reliability. The EP3 makes this possible with its high-precision position control, ena­bling the valve to adjust exactly to the required demand. By eliminating unnecessary air supply and using only minimal compressed air for correc­tive movements, it not only prevents overdosing but also helps significant­ly reduce the plant’s overall energy consumption.

Digital intelligence for modern production processes

Integrated energy monitoring within process control systems offers clear added value: it enables continuous tracking of energy consumption and reveals optimization potential in real time. Smart use of this data not only improves overall performance but also delivers measurable energy savings.

As industrial facilities become increas­ingly digitalized, the demand is grow­ing for intelligent, networked control systems – systems capable of continu­ously monitoring energy usage, iden­tifying issues and faults, and uncov­ering optimization opportunities in real time.

The fully IO-Link-capable EP3 outper­forms traditional systems by offering:

• Seamless integration into industry 4.0 networks
• Real-time monitoring of valve posi­tioning and system parameters
• Minimized downtime through auto­mated diagnostics and fault analysis

Especially in highly automated pro­duction processes, such as semicon­ductor manufacturing and chemical reactors, digital connectivity and real-time diagnostics contribute sig­nificantly to process safety.

Predictive maintenance for maximum efficiency

The EP3 helps to prevent planned out­ages and minimize downtime by deliv­ering accurate, reliable sensor data for predictive maintenance. Its innovative system continuously records critical operational parameters – such as valve position, vibrations, and runtime – and transmits this data in real time to existing analytics and maintenance platforms.

This provides operators with high-qual­ity data, enabling early detection of anomalies and wear patterns – an essential foundation for precise condition monitoring and proactive maintenance. Maintenance activities can be targeted and scheduled in a timely manner, avoiding unnecessary replacement costs and unexpected downtime. Whether in the semicon­ductor industry, where every second of production halt incurs high costs, or in safety-critical sectors like the chemical industry, a reliable predic­tive maintenance strategy optimizes processes and extends the lifespan of industrial assets.

Precise positioning for maximum efficiency

In automated production environ­ments, the accuracy of valve control directly impacts efficiency and process stability. Even slight deviations from the target value can lead to materi­al losses, inefficiencies or excessive energy consumption. The EP3’s highly precise position control prevents these issues from arising in the first place.

Take food production as an example: to guarantee consistent product qual­ity, dosing must be controlled with exact precision. Here, the EP3 not only minimizes material usage but also pre­vents costly batch failures, especially in sensitive applications.

Similarly, in automotive manufactur­ing, precise valve control is essential in paint shops to achieve uniform coat­ing. Modern valve control systems – often combined with robotics and advanced sensor technology – allow real-time adjustment of paint flow, based on factors like coating thickness, robot speed, and booth conditions. This leads to higher product quali­ty, optimized material consumption, and significantly less waste. With the EP3’s exact regulation, material loss is minimized, and quality standards are more reliably met. 

 

Where profitability meets environmental awareness

The EP3 impressively demonstrates that sustainability and profitability are not mutually exclusive – in fact, they can go hand in hand. Companies that adopt this innovative technology ben­efit in multiple ways:

• Reduced energy costs through low­er compressed air consumption
• Extended valve service life thanks to reduced mechanical wear
• Compliance with environmental regulations by significantly redu­cing CO₂-emissions

The EP3 electro-pneumatic position­er stands as a prime example of the move toward sustainable and efficient manufacturing. Its capability to signif­icantly cut compressed air consump­tion, paired with precise control and smart connectivity, makes it a strategic investment for companies truly dedi­cated to sustainability.

Digital connectivity with EBRO Plus

The EBRO Plus app enables mobile monitoring and parame­terization of valve units equipped with EBRO products such as the EP3, SBU Advanced, and SBU IO-Link. It replaces the former “EBRO Connect” app.

Key features:

• Data transfer via Bluetooth (BLE 4.0)
• Connection setup via QR code or device search
• Real-time display of operating status
• Early detection of operational deviations
• Support for commissioning and maintenance