HYDRACTVAL · Project

Water-Powered Control Valves That Cut Dairy and Brewery Energy Bills by 65%

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Every dairy plant and brewery uses hundreds of valves controlled by compressed air — noisy, expensive, and wasteful. A Danish SME figured out how to replace that compressed air with plain water to open and close the valves. The result is a system that uses 65% less electricity, keeps bacteria out (no oily air blowing around food), and gives operators pinpoint control over flow. Think of it like switching from a jackhammer to a precision drill — same job, far less energy and mess.

By the numbers

65%

Reduction in electricity consumption and CO2 emissions vs compressed air

~10

Valve systems manufactured for demonstration

€744,625

EU contribution to the project

Partner — single Danish SME (KM Rustfri AS)

Total project deliverables

The business problem

What needed solving

Food and beverage plants run hundreds of pneumatic valves that waste enormous amounts of energy on compressed air, create contamination risks from airborne bacteria and oil, and offer limited control precision. These plants face rising energy costs, tightening hygiene regulations, and pressure to reduce their carbon footprint — yet the valve technology most of them use has barely changed in decades.

The solution

What was built

The project designed, tested, and manufactured approximately 10 demonstration units of a leak-proof double seat control valve powered by a patented water-based hydraulic actuator, replacing traditional compressed-air systems in brewery and dairy process lines.

Audience

Who needs this

Dairy processing plants looking to cut energy costs and improve hygiene complianceBreweries and beverage manufacturers replacing aging pneumatic valve infrastructureFood plant engineers evaluating alternatives to compressed-air systemsProcess automation integrators serving the food and beverage sectorIndustrial valve distributors seeking differentiated product lines

Business applications

Who can put this to work

Dairy processing

mid-size

Target: Mid-size dairy plants running pneumatic valve systems

If you are a dairy processor dealing with rising energy costs and strict hygiene audits — this project developed a water-hydraulic valve system that cuts electricity consumption by more than 65% while eliminating air-borne contamination risks. The leak-proof design means fewer product recalls and less waste from unintended valve openings. Around 10 demo valve systems were manufactured and tested during the project.

Brewery and beverage production

any

Target: Craft and industrial breweries with pneumatic process lines

If you are a brewery spending heavily on compressed air infrastructure — this project built a water-based actuator that replaces pneumatic valves with precise, leak-free control. It reduces the total number of valves needed per process line and allows smaller, more flexible plant layouts. Energy and CO2 emissions drop by more than 65% compared to conventional compressed-air systems.

Industrial valve and automation supply

SME

Target: Valve distributors and process automation integrators

If you are a valve supplier or automation integrator looking for a competitive edge in the food and beverage sector — this project demonstrated a patented water-hydraulic actuator that replaces compressed air across entire process lines. The technology reduces installation costs, eliminates cavitation, and opens new revenue in retrofit and greenfield plant projects. Around 10 valve systems were manufactured for demonstration purposes.

Frequently asked

Quick answers

How much does the water-hydraulic valve system cost compared to standard pneumatic valves?

The project data does not include specific unit pricing. However, the objective states the technology reduces the number of valves needed per process, lowers production and installation costs, and enables smaller plant layouts — all pointing to lower total cost of ownership. Contact the coordinator for current pricing.

Can this work at full industrial scale in a large dairy or brewery plant?

The project manufactured approximately 10 valve systems for demonstration (deliverable D4.1), targeting brewery and dairy process lines. The technology was designed from the start for industrial food and beverage environments, not just lab conditions. Full-scale deployment readiness should be confirmed with KM Rustfri directly.

Who owns the intellectual property and can I license this technology?

KM Rustfri AS, a Danish SME, coordinated the project as the sole partner and holds the patented water-based hydraulic actuator technology. Licensing or purchase arrangements would need to be negotiated directly with KM Rustfri.

Does this valve meet food safety and hygiene regulations?

The system was specifically designed for brewery and dairy industries where hygiene is critical. The leak-free, sterile hydraulic system prevents spread of air-borne bacteria and oil, reducing food and beverage contamination risks. Specific regulatory certifications should be verified with the manufacturer.

How long does it take to retrofit an existing plant?

Based on available project data, the technology is designed to reduce valve count and simplify plant layouts, which suggests retrofit complexity could be lower than expected. However, specific installation timelines were not published in the project deliverables. The manufacturer can provide site-specific estimates.

Can this be used outside food and beverage — in pharma or chemicals?

The project objective explicitly states the technology has potential to be adapted for other markets currently using pneumatic valves. While the demonstration focused on brewery and dairy, the core water-hydraulic actuator could serve any industry where compressed air drives process valves.

Consortium

Who built it

This is a focused single-company project: KM Rustfri AS, a Danish SME, was the sole partner and used the full €744,625 EU contribution to develop and demonstrate its patented technology. With 100% industry participation and no university or research partners, the project was entirely commercially driven — the company bet on bringing its own invention to market rather than conducting academic research. This makes the results highly practical but means independent validation should be sought separately.

KM RUSTFRI ASCoordinator · DK

How to reach the team

KM Rustfri AS is a Danish SME specializing in stainless steel process equipment. SciTransfer can facilitate a direct introduction to their team.

Order a report on this consortium See KM RUSTFRI AS profile →

Next steps

Talk to the team behind this work.

Want to explore whether water-hydraulic valves could cut your plant's energy costs? SciTransfer can connect you directly with the team behind HYDRACTVAL and provide a tailored briefing for your operations.

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