Smart Valve Technology Eliminates Downtime in Chemical Manufacturing

In the chemical industry, unplanned downtime is more than a nuisance—it’s a direct hit to productivity, safety, and profitability. For a leading global chemical manufacturer, frequent shutdowns caused by aging instrumentation had become an operational bottleneck. Their solution came in the form of an innovative, all-in-one smart valve: the Focus-1 from FOCUS-ON, a collaboration between Bürkert and KROHNE.

The plant’s legacy system relied on separate flow meters, pressure sensors, and control valves, each requiring individual wiring, calibration, and maintenance. This complexity increased the risk of failure at multiple points. In one costly incident, a single instrumentation fault led to a six-hour line stoppage, resulting in significant production and financial losses.

Determined to modernize, the company evaluated alternatives and selected the Focus-1 smart meter valve. This next-generation device combines a control valve, electromagnetic flow meter, and pressure sensor into one fully integrated unit. Its edge computing capabilities allow real-time diagnostics and self-optimization, reducing reliance on central control systems.

Installation proved to be a major advantage. The compact form factor, pre-calibrated sensors, and built-in digital communication made the Focus-1 a true plug-and-play solution. Engineers were able to swap out the old setup and commission the new device within hours, with minimal disruption to operations.

Since deploying the Focus-1, the plant has reported zero unplanned downtime related to instrumentation. Predictive maintenance features monitor key process variables and flag anomalies before they become failures. Operators now have enhanced visibility into process conditions, enabling faster decision-making and more proactive interventions.

FOCUS-1 UK Roadshow

In addition to improved reliability, the team saw tangible gains in process efficiency and cost savings. Fewer components meant reduced inventory needs, lower maintenance overhead, and simplified training for technical staff.

This case underscores a broader trend: the move toward smarter, more integrated instrumentation in process industries. As facilities aim to improve uptime, reduce complexity, and prepare for Industry 4.0, solutions like Focus-1 are rapidly shifting from optional upgrades to essential infrastructure.

For plants still operating with traditional setups, the message is clear—intelligent valve systems, specifically the FOCUS-1 Smart meter valve, are no longer just a future vision. They’re here, and they’re delivering results.

FOCUS-1 UK Roadshow

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