How the Westlock K20 Solved Positioner Failures in a Harsh Environment

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Challenge

A client of ours in the cereal manufacturing industry was experiencing failures with their existing positioners, which required both a 24V DC supply and a 4-20mA signal to function. Positioned at roof level above industrial cookers, these units were struggling in the hot and humid conditions. Additionally, the current positioners had a digital display. The lack of clear visual indicators made local monitoring difficult from ground level, leading to increased maintenance time and potential production disruptions. In short, the client was in need of a dependable positioner suited to use in harsh environments.

Solution

To demonstrate a more reliable alternative, Valve & Process Solutions provided a Westlock Controls K20 Smart positioner free of charge to test on-site. The Westlock K20 offered key advantages:

Only 4-20mA input required ✅ – Simplifying installation and reducing power dependency.

Superior durability in demanding environments ✅ – Designed to withstand extreme conditions without compromising performance.

Iconic Westlock beacon indicator ✅ – Providing clear visual status for easy status checks from ground level.

Quick and simple auto-calibration ✅ – Ensuring an efficient setup process, reducing installation time.

Robust cast adaptor ✅ – Ability to fit the Westlock K20 Smart positioner to your specified actuator (for this application it was a Norbro 40R pneumatic actuator).

Outcome

The client was impressed with the improved reliability, ease of calibration and enhanced visibility of the Westlock K20 Smart positioner. The enhanced reliability meant fewer failures, leading to smoother production runs. As a result, they adopted the solution, ensuring better performance and reduced maintenance downtime on their production line.

"I can’t emphasise how much support VPS have provided me from conducting site surveys on old existing equipment and specifying new in line with our site standards to allow us to utilise stores stock, to solving problems with our current positioners on our cooker steam control valves and retrofitting them with Westlock K20’s. Where others have tried and failed they have succeeded and even taken on some of our service and repair work."

At Valve & Process Solutions, we’re committed to helping manufacturers find innovative and reliable solutions to keep their operations running at peak performance. For industries operating in harsh, high-temperature environments, equipment reliability is non-negotiable. If you're facing similar challenges, get in touch with our team today and let’s discuss how we can help!