In early 2024, a mid-sized chemical manufacturing unit in Tamil Nadu reached out to us with a unique challenge. Their entire process relied on manually operated control valves, and operators had to physically turn each valve to control the flow of hot and corrosive liquids.
The issue?
It wasn’t just time-consuming — it was unsafe, inaccurate, and inefficient, especially during shift changes and emergency shutdowns.
The Challenge
The plant manager explained,
“We’ve got over 40 valves. Our team spends nearly 3 hours every day manually adjusting them. Plus, one mistake could lead to product loss or safety risks.”
They didn’t want to go for pneumatic systems due to the lack of consistent compressed air supply. What they needed was a clean, electrical, low-maintenance solution.
That’s when we suggested Electric Linear Actuators.
Step 1: Understanding the Valve Mechanism
Before integration, we analyzed the type of valve used — mainly globe and gate valves that required linear motion for opening and closing. Perfect for electric linear actuators.
We measured:
- Stroke length needed to fully open/close each valve
- Force required to move the stem
- Speed preference (fast vs gradual)
- Control signals (manual switch or PLC-based)
Step 2: Selecting the Right Actuator
After calculation, we chose industrial-grade IP67-rated actuators with:
- 1000N to 2000N thrust capacity
- Stroke length of 100mm to 300mm
- 230V AC input with modbus-compatible controllers
- Manual override in case of power failure
We also ensured the actuator bracket and coupling matched the valve stem for easy retrofitting.
Step 3: Integration & Testing
We started with a pilot installation on 3 valves.
The actuators were:
- Mounted directly over the valve stem with a custom coupling
- Connected to a local control panel and then to the PLC
- Calibrated to stop at fully open and fully closed positions using limit switches
Within 3 hours, we had full remote control over those valves.
The Result
After 2 weeks of testing, the factory gave the green signal to automate all 40 valves.
- Operator time dropped from 3 hours/day to 15 minutes
- No more manual errors or misalignment
- Emergency shut-off could be done remotely in seconds
- Maintenance reduced drastically since electric actuators are sealed and self-contained
The plant head told us,
“We never thought valve automation could be this simple without pneumatics. Your team made it look easy.”
Final Thoughts
Integrating electric linear actuators into industrial valve control isn’t just about automation — it’s about efficiency, safety, and long-term savings.
Whether it’s chemicals, water treatment, or oil processing — if your system still relies on manual valves, it’s time to think electric.