Bürkert Automates Steam Control, Cutting Energy Costs by 25% at Dart Aerospace Plant

At Dart Aerospace’s Portsmouth facility, a focused energy‑efficiency project pinpointed steam consumption as a major cost driver. In partnership with Bürkert, the plant installed an automated steam shut‑off system that now saves 25 % on energy bills and delivers a rapid return on investment.

Paul Hobden, Account Manager, Bürkert UK, reports.

Aerospace Manufacturing and Steam‑Dependent Processes

Dart Aerospace designs and builds mission‑critical equipment for helicopters and fixed‑wing aircraft. The UK plant in Portsmouth produces flotation devices for emergency water landings and auxiliary fuel cells, among other components.

Core machinery includes 21 presses and spreaders that shape rubber and polymer parts and apply sealants such as Kevlar®. Steam from a central boiler, routed through ¾‑inch and 1‑inch lines, supplies heat to the entire press room.

Challenges of Manual Steam Shut‑Off

Because Dart Aerospace’s production is highly specialised, shifts run only during daylight hours. Each press produces 8–20 moulds per day, and many machines sit idle for extended periods. Despite the presence of manual valves on every unit, steam was often left flowing when equipment was not in use. Closing these valves was physically demanding, sometimes requiring work at height and lengthy shutdowns.

The Maintenance and Engineering Team therefore sought an automated solution that would shut steam off at the end of each day while allowing rapid re‑activation for the next shift.

Designing an Automated Steam Control System

Bürkert’s engineering specialists collaborated with the on‑site team to design a system that automatically turns off steam at 6 pm and can be selectively re‑opened by operators. The design centred on a Type 2000 angle‑seat valve installed on each machine, offering a compact footprint and high‑flow capacity. The self‑adjusting packing gland provides robust sealing, and the stainless‑steel construction ensures long service life.

Each angle‑seat valve is driven by a Bürkert Type 6524 pneumatic valve, controlled from a centrally located Type 8652 valve island. The island, powered by a 24‑V supply and integrated with the plant’s Ethernet network, simplifies maintenance and reduces installation costs by avoiding a dedicated control head for every valve.

Human‑Machine Interface and Automated Control

The valve island connects to a touch‑screen HMI running a custom program from Bürkert’s UK engineering team. Operators can open or close individual steam lines manually, but the system automatically shuts all lines at 6 pm each day. At the start of the next shift, only the required presses or spreaders are re‑enabled, keeping idle equipment isolated from steam.

Rapid Commissioning and Return on Investment

Initial discussions began in September 2024. With the plant’s usual contractor unavailable, Dart Aerospace’s own Maintenance and Engineering team, led by Tony Foster, installed the angle‑seat valves during the Christmas shutdown. Meanwhile, Bürkert’s German headquarters manufactured the valve island, which was shipped to the UK for programming.

On the same day as installation, staff training and system commissioning were completed. The automated steam control system went live in January 2025.

Measurable Energy Savings and Operational Benefits

By January 2026—12 months after commissioning—the system delivered approximately 25 % energy savings on a month‑by‑month basis, benchmarked against three years of comparable production output. The first six months of 2025 alone produced a clear return on investment.

Beyond cost reduction, the automation improved safety by eliminating manual valve operation at height and enhanced process efficiency by ensuring steam was supplied only 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

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Bürkert Fluid Control Systems

Bürkert operates in 35 countries worldwide, working through a global network of distributors to stay close to customers. With a strong research focus, the company invests heavily in R&D, employing 150 experts in its German and French facilities to develop cutting‑edge fluid control solutions.

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We manufacture process equipment and provide end‑to‑end control solutions, from measurement to control units.

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