Stop the Steam: Bürkert Flow Control System Reduces Energy Costs at Aerospace Plant

At a specialist aerospace equipment manufacturer in Portsmouth, a targeted initiative to reduce energy costs identified steam consumption as a key area for optimisation. Dart Aerospace engaged Bürkert’s engineering team to develop an automated system that could close steam flow during non-operational periods. This bespoke flow control system was commissioned in January 2025 and delivered a return on investment within months.

Paul Hobden, Account Manager at Bürkert UK, reports.

Aerospace manufacturing and steam-dependent processes

Dart Aerospace designs and manufactures mission-critical equipment primarily for helicopters as well as fixed-wing aircraft. The global organisation’s UK operation is based in Portsmouth where the plant produces systems including flotation devices that provide buoyancy for emergency water landings as well as auxiliary fuel cells.

Core manufacturing machinery includes presses that form rubber and polymer components into precise shapes and spreaders that apply sealants and bonding layers such as Kevlar®. A wide range of machine types and sizes are used depending on the part in production including 21 presses and spreaders. All of these machines are supplied with steam from a central boiler via a network of ¾ inch and 1 inch steam lines that distribute heat across the press room.

Steam shut-off challenges in specialist production

Production at Dart Aerospace is highly specialised rather than mass-produced and typically operates during daytime shifts rather than continuous 24-hour manufacturing. Each press produces between 8 and 20 moulds per day and machines are not always used simultaneously. Some specialist machines can remain on standby for more than a day.

However steam flow to the machines was often continuous even when equipment was not operating. While each press and spreader had a manual valve to regulate steam flow the supply was not routinely shut off at the end of each day. Closing the valves manually could be physically demanding and some valves were difficult to access, requiring working at height and extended shutdown procedures.

To remove these barriers Dart Aerospace’s Maintenance and Engineering Team sought an automated steam shut-off solution that would reduce unnecessary energy usage and minimise operating costs.

Developing an automated steam control system

To develop the control system the on-site engineering team collaborated with Bürkert as a flow technology specialist. The brief was to design a system that could automatically turn off the steam supply at the end of each day while allowing individual machines to be reactivated during the following shift. This approach ensured operational flexibility while preventing steam from being supplied to idle equipment.

Flow system design and component selection

With all but one machine supplied by a single ¾ inch or 1 inch steam line Bürkert engineers specified a Type 2000 angle seat valve for installation on each machine to provide reliable on off steam control. The angle seat design provides a compact footprint while enabling high flow rates through a virtually straight flow path. When closed the self-adjusting packing gland ensures high sealing integrity while the stainless steel maintenance-free construction delivers long service life.

Each angle seat valve is controlled by a Bürkert Type 6524 pneumatic valve for reliable high-pressure switching. The pneumatic valves are mounted centrally on a Bürkert Type 8652 valve island and switched using a 24 V supply. This centralised architecture with pneumatic hoses delivered significant cost savings and simplified future maintenance compared to installing a dedicated control head on every valve. The Type 8652 valve island also enabled straightforward integration with the plant’s Ethernet network.

HMI integration and automated control

The valve island was integrated with a human machine interface control panel running a bespoke program developed by Bürkert’s UK engineering team. The HMI touch-screen interface allows operators to open or close steam supply to individual machines. 

The system is also programmed to shut down all steam lines automatically at 6 pm each day. At the start of the next shift operators can manually re-enable any required press or spreader while unused equipment remains isolated from the steam supply.

Rapid commissioning and return on investment

Initial discussions at the Portsmouth facility took place in September 2024. When Dart Aerospace’s usual contractor was unable to install the angle seat valves the company’s Maintenance and Engineering team led by Tony Foster completed the installation during the Christmas shutdown in 2024.

During this period the custom valve island was manufactured at Bürkert’s German headquarters and delivered to Bürkert UK for programming. A user-friendly interface was developed to simplify operation. System commissioning and staff training were completed on the same day and the system went live in January 2025.

Measurable energy savings and operational benefits

By January 2026 twelve months after commissioning the Bürkert system was delivering energy savings of approximately 25 percent on a month-by-month basis. This reduction was benchmarked against three previous years of production with comparable operational output. Energy savings recorded during the first half of 2025 alone demonstrated a rapid return on investment.

In addition to direct cost savings the automated steam control system improved safety by reducing manual valve operation and working at height and enhanced process efficiency by ensuring steam was only supplied where and when it was needed.

For further information, please contact:

Paul Hobden, Account Manager

Bürkert Fluid Control Systems:
Tel: +44 1285 64 87 20
Email: sales.uk@burkert.com
Web: www.burkert.co.uk