Process Industry Informer December 2018

www.processindustryinformer.com

DECEMBER 2018 Volume 14 No.6

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

Digitalisation is the best way to get a taste of the future

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Contents

FEATURED ARTICLES DIGITALISATION is the best way to get a taste of the future

PRODUCT SECTIONS

11

PAGE

NEWS & EVENTS

04 – 06

APPLICATIONS

08

HEALTH & SAFETY

10

PROCESS MEASUREMENT & INSTRUMENTATION

12

PAPERLESS RECORDERS

12

SENSORS

13

PUMPS & VALVES

17-18 & 20

FOOD & BEVERAGES

22-23 & 30

TANK CLEANING

29

FILTRATION SOLUTIONS

29

14

OPTIMISING WASTE HEAT RECOVERY BRINGS A RANGE OF BENEFITS TO PROCESSING PLANTS FINDING VALUE

in liquid waste streams

16

21

ELIMINATING lubricant contamination from food processing machinery

25

PREPARING FOR A

SAFETY AUDIT

26

GENERATING OFF-GRID ENERGY

PREVENTATIVE MAINTENANCE MATTERS

28

as winter comes calling

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All product announcements published in Process Industry Informer are paid for. All copy submitted for publication in Process Industry Informer must be legal and must comply with the British Code of Advertising Practice and is accepted for publication, or not, at the publishers’ absolute discretion. When deemed necessary all copy may be edited and classified at the publishers’ discretion. All material contained in Process Industry Informer is published in good faith, but it is emphasised that the publishers do not in circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty expressed or implied by such publication) and that the publishers specifically disclaim all and any liability to advertisers, readers and user of any kind for loss or damage of any nature whatsoever and however arising, whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person.

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December 2018 – Process Industry Informer

03

NEWS & EVENTS

ABB’S UK ENGINEERING CENTRE DOUBLES IN SIZE TO MEET RISING DEMAND ABB has doubled the size of its UK Engineering Centre to tackle demand for servicing variable speed drives (VSDs), developing specialist test rigs (STRs) and customer training.

Floorspace at the site in Coalville, Leicestershire, is increased from 830 m2 to 1789 m2.

The site houses the latest ABB-certified workshop – one of 17 throughout the world - offering repairs and upgrades to low voltage AC and DC drives and medium voltage AC drives.

The facility upgrades third party medium voltage drives, as well as those of ABB. “Many operators across multiple industries are finding that their variable speed drives are no longer supported by the original vendor. ABB can integrate new variable speed drives and control platforms to these systems, ensuring operators can continue to benefit from their substantial investment in equipment,” says Stuart Melling, Business Unit Manager, ABB Drives UK. The new facility houses ABB’s STR business, for which a new class of test rig for electric vehicles, incorporating battery simulators and electric chargers, is being developed.

The location boasts the largest VSD training school in the UK, offering customers access to certified courses covering low-, medium- and high-power drives.

Coalville sees the introduction of the ABB AbilityTM Remote Support Centre. This enables global customers to maximise uptime and optimise processes by having round-the-clock access to drive and automation experts who use cloud-based technologies for preventive and predictive maintenance.

Apprentice Lucy Tudor cuts the ribbon at the opening of ABB’s UK Engineering Centre in Coalville

“Being in the heart of Leicestershire with good access to the M1, M42 and M6 motorways, the Coalville facility is a great location for everything from spares distribution to easy access for customer training,” says Paul T. Williams, General Manager of the facility. “The site is home to some 40 electrical, mechanical, control system and software development engineers, with the team expected to grow in the coming months.”

For more information, call please contact ABB Limited Tel: 07000 DRIVES (07000 374837) E-mail: energy@gb.abb.com Web: www.new.abb.com/uk/campaigns/energy-productivity

POWTECH 2019 – MECHANICAL PROCESSING TECHNOLOGY FOR TOMORROW’S MEGATRENDS The next POWTECH will take place from 9 to 11 April 2019 at Exhibition Centre Nuremberg, where innovations and new approaches for the processing industries take centre-stage in six exhibition halls.

Powder and bulk solids experts from around the world are invited to see the technology and solutions offered by exhibitors live in action. Two forums and an interactive knowledge zone provide expert knowledge for the food, pharmaceuticals and chemicals, glass and ceramics, nonmetallic minerals and recycling segments.

Here, and in the course of professional-level dialogue at the trade fair stands, visitors will get reliable answers to the challenges they face. PARTEC, the international congress for particle technology, will run parallel to POWTECH 2019 under the theme “Particles for a better life”.

At POWTECH 2019, exhibitors will showcase their latest developments for mechanical processes like size reduction, agglomeration, separation, screening, mixing, storage and conveying. The equipment and machinery on display are fundamental to the production processes of numerous industries. “Current industry megatrends such as energy storage or additive manufacturing (3D printing) are inconceivable without mechanical processing technology. At POWTECH 2019, we will be exploring these new application scenarios among others,” says Beate Fischer, Exhibition

Director POWTECH. She draws a positive interim conclusion from the preparations so far: “Currently, around eight months before the start of the trade fair, more than 80 percent of the display area has already been booked. Companies who would like to take part in 2019 should contact us now.”

Exhibitors and visitors from around the world Once again, visitors to POWTECH will encounter market leaders and innovative companies from all over the world.

Registrations have been received from 27 different countries to date, and pavilions from Japan, China and Spain have already been announced. No less than 29 percent of exhibitors and 40 percent of visitors travelled to POWTECH 2017 in Nuremberg from other countries. The internationally renowned PARTEC Congress will also once again attract particle scientists and researchers from universities, institutes and companies worldwide to Nuremberg. More than 500 delegates are expected at the congress, which takes place every three years in the spring parallel to POWTECH. PARTEC is sponsored by VDI-GVC (Association of Process and Chemical Engineering).

For registration documents and more information on POWTECH please go to: www.powtech.de.

BOGE COMPRESSORS ACHIEVES ISO 9001: 2015 STANDARD

IMPRESSIVE SET OF APPOINTMENTS FOR PROCESS ENGINEERING LEADER

A string of new project wins and continued growth has seen BPE bolster its team with several new members of staff.

Phil Bowles joins as a senior biochemical engineer and consultant. He comes with an enviable track record in the industry, holding technical leadership roles with pharmaceutical manufacturing companies and engineering firms.

Andrew Stevenson joins in the role of design lead. Liesel Butler joins BPE as a project engineer, while Barney Thornton and Jack Plested take on the roles of graduate process engineers.

04

Managing director Noel Quigley said: “2018 has been a hugely successful year and, despite some of the understandable trepidation regarding Brexit, we’ve seen a lot of positivity across the whole industry.

For us, there have been several significant project wins as our clients look to expand and update their facilities. These latest appointments signify our commitment to ensuring we have the very best team as we continue to expand.”

For more information contact BPE at Web: www.bpe-ds.com

BOGE has achieved ISO 9001:2015 certification for its UK Operations.

This replaces the previously held 9001:2008 version.

version, there is a greater focus on leadership and management commitment, risk management and performance monitoring.”

ISO 9001:2015 is the latest version of the internationally recognised standard that specifies requirements for a companywide Quality Management System (QMS).

BOGE has been ISO certified for many years, achieving ISO 9000 in 2008.

It also holds SAFE Contractor and CHAS accreditation and is a long standing member of the British Compressed Air Society.

Mark Whitmore, General Manager at BOGE comments, “We’re extremely proud to have achieved this; it’s the leading measure of excellence in manufacturing & operating standards globally and even more demanding than the 2008 version.

“We have adapted and improved some of our processes to meet this enhanced quality management standard. In this

For more information contact: BOGE Compressors Ltd. Huddersfield, West Yorks.

Tel: +44 14 84-719921 Fax: +44 (0) 1484 712516 Web: www.boge.co.uk

Process Industry Informer – December 2018

NEWS & EVENTS

HART TO ETHERNET WHITE PAPER Moore Industries has created a new white paper titled “Bridging the Gap Between HART Devices and IIoT, the Industrial Internet of Things” to address customers’ questions and provide succinct information on HART devices and IIoT This white paper outlines how the flow of process and diagnostics data from smart HART devices can now be shared with mid and higher-level control systems, asset management and data information systems without having to upgrade expensive process control interface equipment.

View the news release for the white paper “Bridging the Gap Between HART Devices and IIoT, the Industrial Internet of Things” . To view this, go to http://www.miinet.com and see White Papers and Articles on Home Page.

DUPONT SUSTAINABLE SOLUTIONS AND GUARDHAT TO DEVELOP SAFETY WEARABLES FOR THE WORK ENVIRONMENT

TOUCHPATH LAUNCHES ONE-STOP MANUFACTURING MANAGEMENT SYSTEM s @4OUCH-ANUFACTURER INCREASES PRODUCTIVITY by up to 30% s %NABLES LEANER MANUFACTURING s #AN BE DEPLOYED FASTER AND AT LOWER COST s 3UITABLE FOR BOTH PROCESS AND DISCRETE manufacturing

“This system captures more information for better manufacturing performance” says TouchPath International CEO David Myers DuPont Sustainable Solutions (DSS) has announced a partnership with industrial safety technology company Guardhat to use smart personal protection equipment (PPE) to provide a safer, more productive work environment. DSS and Guardhat will together develop advanced, scaleable wearables that provide real-time data for industrial companies.

“Industrial companies are capturing incredible amounts of data about their physical assets. This gives companies unprecedented opportunities to improve workflows,” says Davide Vassallo, Global Managing Director for DuPont Sustainable Solutions. “‘Smart’ PPE is the next phase of the digital transformation for industrial companies.”

Saikat Dey, Guardhat Co-Founder and CEO, says, “We combine advanced internet-based technology with dependable PPE to create

December 2018 – Process Industry Informer

a 3D, holistic view of every user’s work environment. This allows us to actively predict and prevent workplace accidents.”

The wearables provide real-time hazard alerts to employees and supervisors while the data allows DSS to advise companies on how to adapt their safety management systems to the real risks their employees face.

For further information, visit www.bit.ly/iDSS-EU. For further information contact: John Michael Kern Tel:+41 22 717 5293 – Office +41 79 720 1538 - Mobile E-Mail john.m.kern@dupont.com Web: www.sustainablesolutions.dupont.com.

International supply chain solutions provider TouchPath (www.touchpath.com) is launching ‘TouchManufacturer’, a fully integrated, lean manufacturing management system that can be implemented rapidly and at lower cost by both discrete and process manufacturers.

TouchManufacturer uses smart TouchPath technology to manage the manufacturing process and measure its performance for each user, increasing productivity by up to 30% say TouchPath.

TouchManufacturer captures data in a timely and accurate manner for all stages of the manufacturing process. Its inventory control, warehouse performance system tracks raw materials, work in progress, finished goods and shipments in real time and increases visibility throughout the order fulfilment cycle, improving shipping performance and

reducing paperwork, inventory/picking errors, transport and administrative costs.

TouchManufacturer’s manufacturing execution system records and displays machine control and other shop floor data accurately and in real time, continuously monitoring production status to enable leaner manufacturing, at lower cost and with less waste. And its advanced, open-industry-standard communications makes shop floor machine data available to manufacturing requirements planning systems, in real time.

“This system captures more information for better manufacturing performance and a faster return on investment” says TouchPath International CEO David Myers. “Our technology enables greater connectivity across manufacturing, ensuring that any and all process improvements benefit the entire enterprise and impact the company’s bottom line.”

TouchPath has operations in the UK (Halifax HX1 5ER) and the USA (High Point, NC 27265).

For more information contact Touchpath, Halifax, West Yorkshire Tel: 01422 399530 E-mail: dmyers@ touchpath.com Web: www.touchpath.com

05

NEWS & EVENTS

BOGE NOW COVERS THE FULL PERFORMANCE RANGE IN OIL-FREE COMPRESSORS WITH THE LAUNCH OF THE EO 11KW BOGE Compressors, extends its EO range of scroll compressors. The new ultra-quiet EO 11 produces oil-free compressed air in the 11kW performance segment and completely eliminates the risk of contamination.

What makes this scroll compressor technology stand out is that it operates without oil lubrication: the aluminium spirals in the compressor chamber interlock but do not touch. The resulting compressed air is pulsation-free and absolutely free of oil.

BOGE now covers the full performance range in oil-free compressors with the launch of the EO 11kW BOGE Compressors, extends its EO range of scroll compressors. The new ultra-quiet EO 11 produces oil-free compressed air in the 11kW performance segment and completely eliminates the risk of contamination.

What makes this scroll compressor technology stand out is that it operates without oil lubrication: the aluminium spirals in the compressor chamber interlock but do not touch. The resulting compressed air is pulsation-free and absolutely free of oil.

FLEXIBILITY BOGE’s control system, focus control 2.0, can regulate up to four EO scroll compressors horizontally with base load switching, thus ensuring efficient control for as many as 16 compressor units.

Mark Whitmore, General Manager, states “We understand how important an oil-free compressed air system is for use in applications such as medical technology, pharmaceutical and food processing. We have set ourselves up to react speedily when customer orders come in and are able to deliver throughout the UK.�

For further information contact: BOGE Compressors Ltd. Huddersfield, West Yorks.

Tel: +44 (0) 14 84 719921 Fax: +44 (0) 1484 712516 Web: www.uk.boge.com/en

DIXON INTRODUCES NEW EZLINK™ ARMLESS CAM & GROOVE

VOLUMETRIC SELF-PRIMING SCREW PUMPS FOR HANDLING OILS & LIQUIDS WITH MINIMUM LUBRICATING QUALITY These screw pumps are volumetric selfpriming pumps suited to handle oils and liquids with a minimum lubricating quality.

The design simplicity makes these screw pumps intrinsically reliable and efficient.

A new push-to-connect positive locking system and low-profile design dramatically improves the ability to easily transfer and unload fuels, water and other liquids.

Dixon Group Europe Ltd, leading provider of hose and coupling solutions, are pleased to launch their new armless Cam & Groove PRODUCT LINE %:,INK˜ 4HE %:,INK SYSTEM IS AN INNOVATIVE DESIGN concept that features an armless positive LOCKING SYSTEM 4HE %:,INK S INNOVATIVE engineering is in stark contrast to conventional CAM GROOVE PRODUCTS %:,INK IS EASIER TO connect, and the new design also requires less maintenance since there are no cam lever arms that tend to break and need replacing.

3IMPLY PUSH TO CONNECT THE %:,INK COUPLER to any standard cam & groove adapter to achieve an ultra-reliable connection. In addition, the product’s low profile allows for easy connection.

Commenting on the introduction of the new product line, Brian Zottarelli, vice president AND GENERAL MANAGER OF $IXON S #AM Groove Division stated, h%:,INK REPRESENTS a major leap forward in cam & groove technology, and it comes as a direct result of Dixon listening to operators and the challenges they face in the field. We responded by developing a new design from the ground up.

We’re excited to offer products that will simplify and improve the transfer and unloading of fuels and other liquids.�

06

!T PRESENT $IXON S %:,INK PRODUCT LINE includes types B, C, D and dust caps in 1½� to 4� in aluminium and from 1½� to 3� in stainless steel. These configurations come with a black Buna nitrile rubber seal as standard but FKM and Fluorosilicone are available on request to offer a low temperature as well as a chemically resistant seal option for various applications.

Other operational and safety features of the %:,INK PRODUCT LINE INCLUDE COUPLER PUSH TABS that can be locked with safety pins and/or a zip tie. ! COPY OF THE %: ,INK BROCHURE IS NOW available direct from Dixon. For more information visit dixoneurope.co.uk or email marketing@dixoneurope.co.uk or contact Dixon on 01772 323529 Dixon is a leading manufacturer and supplier of hose assemblies, fittings, fluid control products and accessories.

Dixon serves a broad range of industries – including the agricultural, chemical, construction, fire prevention and suppression, food and beverage, industrial, mining, petrochemical and pharmaceuticalsegments – by offering the industry’s most comprehensive product line available from a single source.

For further press information please contact Gill Platt @ Dixon Group Europe Ltd on T: +44 (0) 1772 323529 F: +44 (0) 1772 314664 Email: marketing@dixoneurope.co.uk

The accurate hydraulic balance and the special profile of the screw thread guarantee a continuous flow with minimum pulsations and turbulence, resulting in extremely low noise levels even at high rotational speed.

The screws epicycloidal profiling is developed through a complex computerised calculation which not only perfectly defines their shape, but also controls the production with continuous monitoring of machinery process, consequently assuring a high degree of repeatable quality.

The high quality level of these screw pumps is guaranteed by a final testing on 100% of the manufactured products.

Characteristics s #OMPATIble with a wide range of viscosities from 1 to 12,000 cSt and above. s %FlCIENTLY WORKING ALSO AT VERY LOW temperatures (-20°C). s (IGH SELF PRIMING CAPACITY s (IGH ROTATION RATES MINIMISING THE SIZE and cost of the pump. s 3TEADY mOW RATE MAXIMUM EFlCIENCY in heat exchange applications. s 3PECIAL DESIGN FOR SYSTEMS WITH ENTRAINED AIR IN THE LUBRICANT MINIMISING THE vibrations and noise caused by air. s -INIMUM SENSITIVITY TO PARTICLE POLLUTION LONGEST LIFE OF THE PUMP AND CIRCUIT s #ONTINUOUS OPERATING PRESSURES UP TO 130 bar, peak 200 bar.

s 0ULSATION FREE MAXIMUM EFlCIENCY OF filtering applications. s %XTREMELY QUIET Product Options Screw pumps: standard according to API 676, for mineral and lubricating oils also fluids with low lubricating properties (water + oil, HFC, LFO, HFO). Flows up to 5,000 litres per minute and pressure up to 130 bar (200 bar peak). s 3!% COUNTERmANGES s -OTOR PUMP SETS CLOSE COUPLED !# OR DC electric motors. s 0RE ASSEMBLED SYSTEMS WITH BELL housing and coupling arrangements. s 3KID MOUNTED PUMPS WITH OR WITHOUT motor but suitable for horizontal or vertical mounting. s (IGH EFlCIENCY !IR /IL (EAT %XCHANGERS up to 14,000 kCal/h (16kW). s /FF LINE lLTRATION SYSTEMS lLTRATION trolley) and complete stand alone systems, also for machine tools). s 2ELIEF VALVES &LOW RATE FROM TO 1,200 litres per minute and pressure up to 40 bar. s !4%8 APPROVAL FOR USE IN EXPLOSIVE atmospheres: AT%8 :ONE For detailed information and technical specification catalogues see www.jbj. co.uk/screwpumps.html

Process Industry Informer – December 2018

APPLICATIONS

CASE STUDIES: HOW TWO PETROCHEMICAL PLANTS IMPROVED LEVEL AND FLOW MEASUREMENT Managing petrochemical plants requires monitoring a variety of complex processes. Preventing accidents is a key concern, as well as ensuring that no product is lost and that the highest quality is maintained. The level and flow instrumentation used to monitor these processes often makes a significant impact on plant efficiency and safety.

Magnetrol® produces a wide range of level and flow instrumentation that can be used in petrochemical plants. This blog post shares the stories of two plants that improved their petrochemical production and better monitored their facilities by using MAGNETROL products.

PROBLEM: NOT ALL GUIDED WAVE RADAR IS CREATED EQUAL

MOTOR AND DRIVES FROM ABB BRING FARM HISTORY TO LIFE FOR STATELY HOME VISITORS State-of-the-art drives and motor power 200 year old farm machinery used to explain innovation in food production over the centuries.

A farm in Cheshire, UK, is bringing 200 years of agricultural history to life for visitors using a 21st century motor and energyefficient variable speed drives (VSDs).

ABB and its authorised value provider, Central Electrical, supported the Tatton Hall estate’s £1.3 million Field to Fork project by supplying an ABB motor and eight VSDs to run original farm machinery. They also overhauled and rewound existing motors from the 1930s, 1940s and 1950s, while providing motor and drive selection, installation and commissioning services.

Tatton Hall is an historic country estate, incorporating gardens, woodland and a working farm. A major part of Tatton Hall’s Field to Fork project is the restoration of the farm’s Victorian mill, which produced feed for the farm’s livestock using machinery such as grinders and crushers.

Previously run by water power, then steam and, finally, electricity, the grinders and crushers are now powered by eight ABB general purpose drives, rated from 2 kilowatt (kW) to 18.5 kW. The VSDs provide a ‘soft start’ which, together with running the mill machinery at lower speed, reduces excessive wear and extends the operating life of the machines.

The farm’s miller can use a mobile phone or iPad, connected remotely to the VSDs, to control the grinder and crusher motors to enable them to talk through the demonstrations at different speeds.

On the ground floor of the feed mill, a VSD is used to operate a hammer mill which crushes barley, wheat and oats into pig meal. On the first floor is a crushing and grinding machine for preparing cattle feed. Other VSDs run a winnower, a mixer and a sack hoist used to take heavy sacks up to the first floor storage room.

An ABB industrial drive is used to run a refurbished steam engine, which originally powered the other farm machines.

The VSD solved a problem of excessive vibration during engine startup. This vibration threatened to damage the mill’s foundations. The VSD controls the engine’s motor and gear box to give a soft start, avoiding the vibrations.

For more information contact ABB Ltd on Web: www.abb.com

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it was the only device tested that could produce reliable measurements with a completely dry probe, a probe having only one of the two process media present, and under varying interface conditions.

PROBLEM: MEASURING BLANKETING GAS TO REDUCE COST An oil & gas and petrochemical company in China required nitrogen tank blanketing for their flammable liquid containment. Monitoring the nitrogen was essential to account for leakage and verify flow going into the vapor space of the tanks. Due to the number of tanks, the gas flow was monitored to find the right balance between the necessary nitrogen usage and potential cost savings.

SOLUTION: MAGNETROL recommended its Thermatel® TA2 thermal mass flow meters to monitor the nitrogen for tank blanketing. The meters came fully calibrated and configured so the company could simply install them and power up. THERMATEL TA2 flow meters are very effective in extreme low gas pressures, such as in tank blanketing applications.

One of the world’s largest oil & gas and petrochemical companies was having problems with multiphase applications involving hydrocarbon level with water bottoms and gas vapor space. Guided wave radar (GWR) technology was introduced to monitor these applications.

However, the GWR devices selected did not produce a reliable signal throughout the measurement range, and the dynamics of the interface made it difficult to distinguish between the upper level and the water below. There was a threat of loss of primary containment (LOPC) due to these measurement errors.

SOLUTION: MAGNETROL pioneered GWR technology for level measurement and its latest device, the Eclipse® Model 706, is considered the highest performing GWR level transmitter on the market. The ECLIPSE Model 706 was tested side-by-side with multiple GWR competitors for both top level and interface measurements and it was proven to be best-in-class.

RESULT: Total cost of ownership was reduced with calibration verification procedures that could be performed in the field.

Since calibrations can cost tens of thousands of dollars and cause process downtime or loss of measurement, this saved money and increased efficiency for the company.

RESULT:

More Information

The ECLIPSE 706 tracked level up to the device’s flanged process connection, above 100% level, with no dead zones or blind spots at the top of the probe. It prevented LOPC by tracking the top hydrocarbon level through the vapor space and also measured the interface (water bottom) due to the superior signal strength. In summary,

MAGNETROL offers numerous level and flow solutions for ethylene applications, including petrochemical production. To learn more about the products we offer and how they can help increase the efficiency and safety of petrochemical plants, download our ethylene brochure.

BREDEL PUMPS SAVE SLOVENIAN WASTE WATER TREATMENT PLANT TIME AND MONEY s "REDEL Pumps replace troublesome progressive cavity (PC) pumps s 2EDUCTION IN MAINTENANCE ALLOWS RETURN ON investment in just 12 months. s .2 %NDURANCE HOSEs provide impressive lifetime handling abrasive sludge Celje is the third largest city in Slovenia and sits at the junction of the Savinja, Hudinja, Ložnica, and Voglajna rivers in the lower Savinja Valley.

Serving a population of 85,000 people, the city’s waste water treatment plant (WWTP) used two progressive cavity (PC) pumps to feed a centrifuge with settled sludge.

The abrasive nature of the sludge meant that the PC pumps suffered stator and rotor wear, leading to a drop in flow rates, as well as the need for regular maintenance downtime. Maintenance often took several hours to complete and required expensive spare parts.

To reduce costs in the Celje WWTP sludge handling duty, Watson-Marlow Fluid Technology Group recommended two Bredel 65 peristaltic hose pumps, fitted with abrasiveresistant NR Endurance hoses, as replacements for the troublesome PC pumps.

Bredel hose pumps have no seals, diaphragms, glands, immersed rotors, stators or pistons to leak, clog or wear.

And, unlike other pump types, viscous, grit-filled sludge

does not affect their performance. The hose is the pump; a single component change is usually the only maintenance required, with time to change a hose measured in minutes rather than hours.

Bredel’s NR Endurance hoses are providing an impressive lifetime of between 10 and 12 months, significantly reducing the need for maintenance downtime, enabling the waste water treatment plant to achieve a return on investment in just 12 months.

For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall.

Tel: 10326 370370 E-mail: info@wmftg.com Web: www.wmftg.com Process Industry Informer – December 2018

HEALTH & SAFETY

REMOVAL OF MICROPLASTICS FROM WATER STREAMS USING MEMBRANE TECHNOLOGY

Martindale Electric – UK market leaders in safe isolation – is pleased to announce the arrival of its latest CABLOK series, which provides installers and maintenance teams with a simple and reliable solution for locking off multiple breakers, switches and valves, to prevent the re-energising of circuits and systems during maintenance, as part of a safe isolation procedure.

The removal of microplastics from drinking, process or wastewater streams is a major step towards the reduction of microplastic pollution found in the environment.

The use of plastic microbeads in cosmetics and personal care products has already been banned in the UK and many other countries.

However microplastic pollution is still being generated by the waste plastics already in the environment which are aging and self-abrading on a very wide scale. As a result, most water sources now contain background but rising levels of microplastic contamination, which can ultimately feed back into in the human food chain.

Crossflow Membrane Technology (CMT), renowned for its success in the removal of bacteria, pesticides, suspended solids and colour from wastewater, is now a practical solution in the fight against the microplastic pollution found in most wastewater streams.

CMT works as a physical barrier against microplastics where the particulates cannot pass through the membrane on the basis of particle size, allowing only crystal clear commercially sterile, particle free water to be discharged. All the microplastic particulates and other separated impurities are safely retained in a low volume controllable form ready for further treatment.

Axium Process specialises in Crossflow Membrane Technology and is working with companies wishing to evaluate the benefits of

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MARTINDALE OFFERS A FLEXIBLE SOLUTION TO SAFE ISOLATION

membrane filtration as a treatment for wastewater and removal of microplastics. The company’s expertise is in the design, build and commissioning of customised membrane filtration plants that can provide cost effective solutions in terms of reduced water and energy costs, recovery of chemicals, reduced effluent volumes and disposal costs.

Axium Process also maintains a comprehensive range of mobile membrane filtration pilot plants and in-house laboratory services which are offered as a research facility for companies wishing to develop and optimise their processes.

For further information please contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Email: gale.rudd@axiumprocess.com Web: www.axiumprocess.com

The latest range of adjustable cable lockouts feature a flexible, PVC-insulated steel cable which is easy to thread and, can be simply adjusted to suit the required length before locking off with a simple squeeze action.

Incorporating a built-in safety hasp, with space for up to six padlocks to be securely fixed, it allows multiple operatives to safely work on the same system. For additional safety, the system cannot be re-energised until all padlocks have been released.

enabling compliance with HSG85, Electricity at Work Regulations.

Martindale Electric is a specialist in providing equipment to ensure safe working on electrical circuits and has designed a wide range of lock out kits and safety equipment, such as voltage indicators, proving units and safe isolation locks to ensure maximum safety in the workplace.

For more information, please contact Martindale Electric on 01923 441717 or visit: www.martindale-electric.co.uk/

Suitable for both the electrical and industrial market, the new ergonomically designed CABLOK series is available with 1m, 3m and 5m cable lengths and is compatible with the Martindale Electric PAD10 and PAD20R padlocks.

The new range of adjustable cable lockouts from Martindale Electric make it easy to ensure all types of circuits can be deenergised and properly isolated prior to maintenance of plant and equipment, preventing potentially fatal accidents and

Process Industry Informer – December 2018

FEATURE / ADVERTORIAL

Filip Schiettecat - Senior Director Industry Management, Siemens PLM Software

Digitalisation is the best way to get a taste of the future

By Filip Schiettecat, Senior Director Industry Management, Siemens PLM Software

BY DEFINITION, THE FOOD AND BEVERAGE INDUSTRY IS FAST MOVING AND ALWAYS CHANGING; MILK GOES OFF, BREAD GETS EATEN, AND WE WANT TO EAT MORE SALADS IN THE SUMMER. But the combination of changing consumer demand, increasing regulation, complex supply chains for global sourcing and distribution, and competition from agile new competitors means food and beverage companies have to move faster than ever. And they have to do all that while still keeping quality high and appealing to customers who want products that suit them perfectly – whether that means gluten free, low sugar or even custom flavours.

Market predictions say there will be more changes in consumer packaged goods in the next five years than there have been in the last fifty.

The only way to keep up is digitalization, which is your best opportunity to reduce time to market, improve efficiency and get ready for the future of manufacturing.

It’s very common for food and beverage companies to be fragmented; that’s not just different departments like product development and marketing, but different product lines will come from different teams who just aren’t connected. If you make both pasta and cheese, they might end up in the same shopping basket and even on the same plate, but if there’s poor communications between the teams behind them you miss out on opportunities to save time and money by sharing information about suppliers and ingredients, process technologies and the shopper who’s buying both of them.

Even within the same product line, entering the same information about ingredients over and over again at different stages of the process means the chance to make a mistake every time that information gets recorded.

Using a digital thread means information only needs to be entered once and can then be re-used at every stage of the process: from creating the first model of the product that allows you to calculate its nutritional profile, through finalising the product formula and recipe in the lab, to monitoring the whole manufacturing chain and tracking those ingredients from multiple suppliers all the way to your final customer. This kind of traceability is key for keeping products consistent and delivering high quality, as well as being able to comply with regulations and keep recalls as limited and transparent as possible. Managing all of this digitally also saves you money and time.

Driven by fashion, social media, broadening interest in different cuisines and increasing concerns about health and allergies, consumer habits and tastes are changing faster than ever. Shoppers want new and interesting products; they want high quality and low prices on everyday items. They want detailed information about what they’re buying, from where and how it was grown to nutritional and allergen information. They want to know if a fruit snack is made with whole apples, apple puree or

December 2018 – Process Industry Informer

Brewery Digital Transformation

freeze-dried apple powder. One day a consumer might be looking for products with alternatives to sugar; next week they might be concerned about artificial sweeteners.

They want more choice of products, in exactly the right pack size for them. They even want custom products, whether that’s a new flavour of an old favourite, a lowcalorie or allergen free option or personalised packaging.

Mixing up different soft drink flavours in a phone app, 3D printed chocolate souvenirs from your holiday or a pack of cookies with your name and design printed on them might be novelties today, but they’re a sign of the trend to more and more differentiation.

At the same time, the price of raw materials is rising, as are the numbers of regional and global regulations. The EU, for example, is currently proposing rules to increase consumer transparency for ingredients like enzymes and flavourings, GMOs, food and feed additives, smoke flavourings and even food contact materials, as well as cracking down on companies who use the same advertising for products made with different ingredients in different countries.

Food and beverage companies need to track and label ingredients for an ever-increasing variety of products and recipes, coming from different suppliers and shipping into different markets around the world through multiple supply and distribution chains. Paper-based processes simple can’t handle the scale and complexity. The bigger your product portfolio, the more variance, volume, complexity or different country regulations you deal with, the more digitalization can help. It’s also a key first step to prepare for the future.

That future is digital food: not the food pills of science fiction but wine, beer, cheese, meat and vegetables that have been tracked from the field and farm into the factory for consistent quality.

Dairy Digital Factory

MANUFACTURING WILL DETERMINE THE FUTURE To meet those market demands, you need to develop multiple product variations, which may require different production lines – often more products and processes than you can create and test with traditional methods.

Again, digitalization is the way to cope. Creating a digital twin for new products and the processes you’ll use to manufacture them lets you design and simulate product performance to make sure every new variant meets compliance regulations and market needs before you even prototype it at lab scale, so you can scale up quickly, manage testing in production to make sure your production matches what was designed, and track which ingredients from which source make it into which product shipped to which customers. A digital twin can reduce how long it takes to get a new product onto the market by up to half.

Using sensors and automation to handle the milk arriving in a dairy and the fermentation of the cheese it’s used to make can cut production time in half and reduce energy costs without compromising quality. Digitizing cellars and fermentation tanks gives brewers better control over temperatures as well as telling them when they can decant a batch of beer and clean the tanks, given them more time to experiment with beer recipes and letting them brew more varieties of beer without needing to buy more equipment. Recording the pesticide levels in the vineyard and sending alerts if the temperature in a fermenting barrel of wine is too high or too low keeps costs down and the quality of the final bottle of wine up.

This kind of sophisticated monitoring and automation may be the exception rather than the norm today, but can you count on your competition not making those investments?

To benefit from this kind of flexibility, consistent quality and reduced costs for your own processes, and to get your share of market opportunities that 3 billion new customers will generate by 2020, it’s time to start implementing your digitalization strategy now.

11

PROCESS MEASUREMENT & INSTRUMENTATION

A BRITISH FIRM HAS DEVISED A DEVICE TO SAVE TIME AND MONEY FOR THOUSANDS OF COMPANIES

HIGH-PRESSURE FLOWMETER MEASURES LIQUID REFRIGERANTS

Adding water to powder or granule mixes has long been done using pails or hosepipes. Time consuming, open to accident and operator error, there has never been a viable alternative. Aquameter Ltd looks set to change that.

Their micro-controlled Abacus system delivers exact, pre-selected quantities of water from a single pipe -straight into the mixing vessel. This precise metering of the water means the operator can recreate batch consistency each time.

Operation is simple - the quantity of water required is programmed in, the RUN button pushed, and the water flows. A solenoid valve located in the water pipe closes the flow at the completion of the cycle - when the pre-set quantity has been reached.

The unit is already in use world wide. Derek Baxter, International Projects Director with Filtrona International in Jarrow, says of the system: “We use the unit for metering water into a carbon-powder mix. Were it not for these units we would be using buckets of water, a line of hose, or a constantly changing mark on the tank - not that convenient.�

He goes on: “With this thing we just dial new numbers in, and away we go - it’s obviously more accurate; using the meter than relying on staff to put it in by pail. “

Titan Enterprises, a leading manufacturer of specialist flowmeter, reports on the development of a high-pressure turbine meter for measuring the flow of liquid refrigerants.

For further information please contact; John Morton aquameter limited 8 Woodlands Drive HODDESDON EN11 8AZ Tel: 01992 442 861 E-mail: john@aquameter.co.uk Web: www.aquameter.co.uk

In response to their OEM customer’s requirements, Titan Enterprises designed a flowmeterable to deliver reliable, high performance across 6 flow ranges from 0.05 to 15 litres perminute. To ensure the highest degree of inertness to the refrigerant fluids the flowmeterpolymer components were moulded in an FDA approved grade of Polyvinylidene difluoride(PDVF) and mounted in a 316 stainless steel body.

Incorporating steel reinforced polymer components, to give a pressure rating of 40 Bar, the low inertia turbines of the flowmeter have proven ideal for measuring the low viscosities (0.3 to 0.4 entipoises) encountered with volatile refrigerant fluids measured in the liquid form. With careful sensor selection the pressure drop through the flowmeter is low enough to prevent gas break-out and ensure reliable flow measurement from -25°C to +125°C. To discuss development of an application optimised flowmeter please visit www.flowmeters.co.uk or contact Titan Enterprises on Tel: +44-1935-812790 E-mail: sales@flowmeters.co.uk

PAPERLESS RECORDERS

ABB TOUCHSCREEN PAPERLESS RECORDER GETS POWERFUL NEW FEATURES !"" S 26' PAPERLESS TOUCHSCREEN recorder now offers a range of powerful new functions.

Users can now create user-customisable process views that can be populated with operational information. Up to seven custom views can be uploaded to a single recorder.

For energy monitoring applications, the RVG200 also offers an optional energy calculation function, enabling accurate calculation of heat energy in water and steam flows.

Another new feature is remote operation.

Enabling users to access recorded data via a PC, tablet or smartphone, this feature can help organisations save cost and utilise staff more effectively.

“As industry increasingly moves towards introducing digital technologies into their processes, the ability to collect, access and utilise data is becoming ever more important,� says Martin Binney, Global Product Line Manager - Recording and Control for ABB Measurement & Analytics. “With its new range of functions, combined with its core features such as touchscreen operation, scalable I/O and secure data recording, the RVG200 provides an ideal solution for any application where fast and reliable access to accurate process data is needed.�

For more, visit www.abb.com/ recorders, email enquiries.mp.uk@.gb.abb.

COM OR CALL REF @26'

With stringent legislation covering product quality through to discharges to air and water, operators must prove their data was collected using a properly configured device. The RVG200‘s configuration report generation function lets users export configuration settings as a CSV file for printing or incorporating into an electronic report.

12

Process Industry Informer – December 2018

SENSORS

HOFFMANN + KRIPPNER LAUNCHES NEW MINIATURE P53 ULTRASONIC SENSOR ‘SMART’ SENSOR PROVIDES CONTINUOUS FEEDBACK & DIAGNOSTICS A smart valve sensor which provides continuous feedback and essential diagnostics to help plant operators ensure optimum process performance has recently been introduced by sensor specialist ifm electronic.

The MVQ smart valve sensor provides outstanding, all-round position visibility with bright multi-coloured LED indication helping plant operators to monitor the flow of media from a distance. For example, is the valve open or closed? Is the valve opening fully?

Or is it blocked by deposits?

Is it closed properly, or is the seal wearing?

If used as a standard sensor the MVQ will provide 3 switched signals for the valve position. However, thanks to the integrated IO-Link interface the sensor becomes a realtime diagnostic device providing continuous real-time feedback, as opposed to a simple, less sophisticated valve position sensor.

December 2018 – Process Industry Informer

The first ultrasonic sensor in a completely encapsulated, gap-free stainless-steel housing EHEDG CERTIFIED FOR HYGIENIC EQUIPMENT DESIGNS

The fine resolution of just 0.1º provides operators with accurate information on the conditions inside the valve, with adjustable tolerances to allow for different types of media and the age of the valve. In addition, the MVQ can also measure the time taken for the valve to move, alerting operators to the possible need for maintenance.

Any end position of the valve and the size of the sensing range can also be set.

Also, a third switch point can be selected, for example for 3-way valves or for a diagnostic alarm. This flexible configuration is enabled with the smart valve sensor by the ifm application software LR Device or an inductive ‘teach button’.

For more information contact: Jon Morris, ifm electronic ltd, Hampton, Greater London.

Hoffmann + Krippner is proud to announce the availability of the new model P5380-D18. This new compact (45mm long and 18mm diameter) ultrasonic sensor is one of the smallest ultrasonic sensors on the market worldwide and is designed for use in harsh environmental conditions as well as in hygienic applications.

Due to the special housing construction made of V4A stainless steel (1.4404) with a roughness depth of 0.6µm, the P53 STEEL HEAD is well suited for use in harsh environments such as dust, moisture and water vapor. As the sensor and its mounting assembly can besanitized with strong cleaning materials, the P53’s real world applications include manufacturing, food and chemical processing, medical, agriculture, packaging, etc. It can be used for a variety of distance measurements as well as level measurement, presence detection, detection of moving objects, counting objects and checking for completeness.

According to Jens Kautzor, CEO of Hoffmann + Krippner, “The P53 is perfect anytime a machine requires a small profile, reliable and cost-effective ultrasonic sensing solution that is easy to install and to clean.”

The new miniature P53 provides a range of up to 800 mm. The high temperature range of up to + 80 °C opens up a wide range of applications.

The data sheet and additional tech details are available at www.hoffmann-krippner. com/downloads-ultrasonic-sensors/ and www.hoffmann-krippner.com/pil-p53datasheets/ For more information, please visit www.hoffmann-krippner.com or contact Sabrina Huschens, Marketing + Inside Sales Mgr. s.huschens@hoffmann-krippner.com +1 (770) 487-1950

Email: Enquiry.gb@ifm.com Tel: +44 (0) 20 8213 2222 Web: www.ifm.com

13

FEATURED ARTICLE

By Matthew Crewe, Managing Director of Green’s

Optimising waste heat recovery brings a range of benefits to processing plants says Matthew Crewe, Managing Director of Green’s Given the need to reduce carbon emissions, protect our environment and reduce fossil fuel consumption, waste heat recovery is increasingly important. There are various ways that this can be done depending on the processes that are being undertaken that result in waste heat, the applications that the captured waste heat is going to be used for and the size and location of the plant.

Components ready for assembly

In processing plants, a waste heat recovery system will usually include economiser/s and/or a waste heat boiler.

An economiser unit is typically installed on the exhaust system from a steam and hot water boiler to reduce the flue gas temperature and increase the thermal efficiency. This will be formed of an appropriate tube configuration that will be determined by taking into account the type of fuel that is being burnt, the temperatures that are being handled, pressures and the space available.

A waste heat boiler recovers heat from hot gas streams, that still have a relatively high energy content which would otherwise go up the chimney and out into the atmosphere.

Capturing the exhaust energy from diesel or gas engines by reducing the flue gas temperature from, for example, 400°C to 180°C, allows processing plants to maximise energy usage and increase production efficiency.

FOR A HEAT RECOVERY CAPITAL INVESTMENT PROJECT, PLANT MANAGERS WOULD NEED TO CONSIDER THE FOLLOWING FACTORS FOR THE RETURN OF INVESTMENT (ROI): s !VAILABLE WASTE ENERGY IN THE EXHAUST GAS SYSTEM s -ANUFACTURING AND INSTALLATION COST OF THE HEAT RECOVERY UNIT s 0HYSICAL SPACE AVAILABLE IN THE PLANT FOR THE HEAT RECOVERY unit s %FlCIENCY SAVINGS BASED ON PLANT OPERATIONAL HOURS s &UEL COST SAVINGS FROM INCREASED PLANT EFlCIENCY s 2EDUCING CARBON AND HARMFUL EMISSIONS

COMMON APPLICATIONS FOR REUSING THE WASTE HEAT THAT HAS BEEN RECOVERED : s PRE HEATING COMBUSTION AIR FOR BOILERS OVENS AND FURNACES s PRE HEATING FRESH AIR USED TO VENTILATE THE BUILDING s HOT WATER GENERATION INCLUDING PRE HEATING BOILER FEED WATER s DIRECT STEAM GENERATION FOR PROCESS OR POWER GENERATION s SPACE HEATING s DRYING s OTHER HEATING OR PRE HEATING FOR INDUSTRIAL PROCESSES However, before a waste heat recovery system can be designed for a processing plant to obtain these benefits, managers need to provide the supplier with information that will help to inform an effective system. This includes the type of fuel that will be used and data about the flue gas including flowrate, composition and inlet temperature. It is, of course, essential to know where the system will be located and the space available which will be used to determine the best materials and tube arrangements.

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On-site repairs team

Using this information, the supplier will work on the optimum thermal design which will include outputs such as the best working fluid i.e. water, saturated steam, superheated steam or thermal oil, flowrate, thermal duty, waterside pressure drop, gas side pressure drop, working fluid outlet temperature and operating pressure.

All of this information will then be used to formulate pressure part calculations and develop the mechanical and structural design that specifies factors such as the system’s weight, width and length and, in some cases seismic calculations and wind loading calculations.

Use of systems in processing plants brings particular challenges for their waste heat recovery systems. For example, if the plant has a dusty atmosphere, this will influence the types of tubes that are used and which fins are employed. Generally, the fins need to have relatively large gaps between them, which is known as a wide pitch specification. They also need to have as high a heat transfer surface as possible making H-finned tubes a frequently specified solution.

The environment in which equipment operates, varying quality of feed water and rigorous operating patterns can result, over time, in reduction in efficiency or even total machine failure.

To avoid this, it is vital to commission a proactive inspection service to identify potential problems with waste heat recover equipment so that they can be addressed in order to maintain optimum efficiency and before they become unnecessarily costly or result in avoidable downtime.

This will usually include examination of the internal surfaces of the economiser and waste heat boiler during planned outages to ensure fouling and erosion issues are not occurring and online cleaning equipment such as soot blowers, are operating correctly. Typically, a comprehensive report will be submitted to the client after the examination work, stating the condition of the examined surfaces and recording corrective measures needed so that a plan can be put into place that keeps these vital pieces of equipment working efficiently.

Processing plant managers should also ensure that their chosen supplier has the required experience, track record and industry accreditations to be able to design and manufacture a system that meets all regulatory and insurance needs.

This can only be achieved by companies that have stringent quality and technical assessment processes in place and is best checked by visiting their facilities to see what they offer first hand.

Having invested in a waste heat recovery system with the aim of making energy usage more efficient and reducing costs, it is highly recommended to initiate a planned maintenance programme to ensure that its lifespan is extended as much as possible and that unplanned outages are minimised.

Components leaving Green’s factory

Process Industry Informer – December 2018

FEATURE / ADVERTORIAL

By Matt Hale, International Sales and Marketing Director at HRS Heat Exchangers

Finding value

in liquid waste streams

Waste is increasingly being viewed as a resource. From well-established practices such as recycling paper and aluminium, to the development of the circular economy, an increasing volume of resources are now being recovered from materials that were previously seen only as inconvenient wastes. Matt Hale, International Sales and Marketing Director at HRS Heat Exchangers, looks at how value can be extracted from liquid waste streams and what to consider when choosing technology to achieve this.

WHY RECOVER WASTE? Waste valorisation is the process of recovering value from waste materials, for example through reusing or recycling them, or by composting or anaerobically digesting them and converting them into more useful products such as materials, chemicals, fuels or other sources of energy. In a circular economy, compared to a linear one, the materials within products are reused, turning previously burdensome wastes into valuable resources.

The European Union has proposed to double its rate of resource productivity by 2030 and as part of this, adopted a communication, Towards a circular economy: a zero waste programme for Europe, in July 20141 . Like key industrial stakeholders and businesses, it asserts that moving to a circular economy can have a positive effect on economic growth and strengthen the competitiveness of companies, in addition to providing a number of environmental benefits.

EXAMPLES OF RESOURCE RECOVERY While we are still a significant way away from the commercial development of large scale biorefineries which can treat wastewater streams to produce a range of products including biofuels, energy, fertilisers, metals, inert media and a whole range of fine chemicals, parts of this process are already established. The use of anaerobic digestion (AD) to recover energy and create organic biofertiliser (digestate) from food and sewage waste is now widespread, and there are various examples of material recovery from different waste streams at all scales, from early research through to fully commercial recovery units at industrial facilities and water treatment works around the world.

Some examples of this type of material recovery include: s 2ECOVERY OF KEY NUTRIENTS SUCH AS PHOSPHOROUS FROM sewage streams for use as agricultural fertilisers. s 4HE POTENTIAL RECOVERY OF BIOPOLYMERS SUCH AS polyhydoxyalkanoates (PHAs) and polyphenols from the wastewater from olive mills.3 s #HEESE WHEY WASTEWATER #77 COMPRISES WASTE streams including whey and wash-out water, and could be treated using various processes to produce a range of products which are useful in food manufacturing and pharmaceuticals, such as whey proteins, peptides, lactose, glucose and other useful chemicals. s 4HE RECOVERY OF SPENT YEAST PRODUCTS FROM VARIOUS processes for use in food production, such as stabilising and pH buffering. Fruit processing is another sector that is ideally placed to capitalise on the potential value of some of its waste products. Citrus peel waste accounts for up to half the total volume of citrus fruit processed globally and contains up to 80 per cent water. It is a potential source of many useful products including dietary fibre, antioxidants, food colorants and flavours, and contains a wide variety of compounds including cellulose, pectin, sugars, hemicelluloses, flavonoids and essential oils such as D- limonene.

MOVING TOWARDS ZERO LIQUID DISCHARGE

UNLEASHING THE POTENTIAL FOR LIQUID WASTE STREAMS Wastewater treatment and ‘water mining’ has also been identified as a key platform on which to base the technological development of such circular production systems 2 . Effective water treatment and material recovery can provide a double economic return. Every cubic metre of recycled or reused water results in a corresponding reduction in mains water demand and wastewater discharge. There are also benefits in terms of the energy and carbon footprints associated with material recovery when compared with primary extraction and processing, together with further environmental benefits arising from reduced waste disposal impacts.

In addition, researchers are increasingly identifying food processing and supply chain waste streams as a major resource for the development of bio-based products and processes, suggesting that the valorisation of food waste should focus on both commodity and higher-value speciality products.

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:ERO LIQUID DISCHARGE :,$ IS A TECHNIQUE BY WHICH LIQUID waste streams are eliminated. Instead of being discharged at the end of the treatment cycle, any wastewater is purified and recycled, while other residues, which often include the type of valuable by-products mentioned above, are extracted.

6ARIOUS PROCESSES ARE EMPLOYED IN :,$ INCLUDING membrane bioreaction, reverse osmosis, electrolysis, filtration and more. However, evaporation is also a key process, both in order to concentrate residues sufficiently to allow their economic extraction or physical removal, and as part of the water purification process.

However, solid-liquid mixtures are complex and it is important that the first stage of any potential project includes a research study to evaluate the nature of the waste stream/s and the saturation levels required. In laboratory experiments, HRS evaluates the maximum concentrations that can be reached for different temperature regimes. This then determines the type of equipment we design.

THE IMPORTANCE OF EVAPORATION (23 (EAT %XCHANGERS HAVE BEEN INVOLVED IN :,$ PROJECTS IN Europe using evaporation systems, including the recovery of potassium and sodium sulphates from organic brine waste streams. A typical HRS process might consist of three steps as follows: 1. Evaporation/concentration (using one or more evaporators depending on the materials involved and the level of concentration required) to levels above the saturation point at high[ temperature.

2. Cooling down of the product to provoke the formation of salt crystals.

3. Further crystallisation in specially designed tanks and separation of the crystals that are formed to allow them to be processed for use. In the third step, a supernatant layer of concentrated solution remains after separation of the crystals. This solution is returned to the second evaporator for concentrating again to above its saturation point.

CORRECT HEAT EXCHANGER CHOICE FOR PRODUCT RECOVERY Both the evaporation and cooling steps result in a high degree of material fouling on the inside of the equipment, so HRS Unicus Series scraped-surface heat exchangers are used to maintain thermal efficiency and remove fouling as it occurs. Coupled with HRS R Series coolers and customdesigned crystallisation tanks, the result is an efficient process which can work continuously without requiring scheduled downtime.

In the example above, two evaporators are used to concentrate and remove pure water from the solution, which can be used elsewhere. The coolers and crystallisers produce solid crystals, and the remaining solution returns to the evaporation process. No liquid waste remains after the process, so that as well as recovering valuable salts, waste management costs are also reduced.

For example, at high temperatures more salts may be dissolved, compared to low temperatures.

Process Industry Informer – December 2018

PUMPS & VALVES

PFEIFFER VACUUM PRESENTS NEW TWO-STAGE ROTARY VANE PUMP PASCAL 2021 HW s (IGHEST VAPOR CAPACITY IN ITS CLASS s )DEAL FOR WORKING WITH AGGRESSIVE GASES s &LEXIBLE AND ADAPTABLE

METERING PUMPS COMBINE REPEATABLE ACCURACY WITH OUTSTANDING RELIABILITY AND ENERGY EFFICIENCY A new range of high pressure metering pumps which offer important features and benefits such as virtually pulse-free operation, consistent high accuracy and outstanding hydraulic efficiency, are now available from pumping specialists MICHAEL SMITH ENGINEERS.

With the new Pascal 2021 HW, Pfeiffer Vacuum presents the two-stage rotary vane pump with the highest vapor capacity in its class. It is optimally suited for all applications where water vapor is expected, such as low temperature sterilization and drying. An optimized design and gas ballast system allows to pump large volumes of vapor without condensation inside the pump. This prevents accumulation of fluid that would adversely affect the service life of the pump and the oil.

Thanks to the materials used, the Pascal 2021 HW also resists aggressive chemicals such as hydrogen peroxide. The pump is ready to deliver vapor in just a few minutes due to a customized temperature management. It has a safety device that impedes the ingress of water into functional sections if the steam capacity is inadvertently exceeded.

With accessories such as oil mist filter and inlet traps, the pump can be ideally adapted to most processes.

Thanks to its compactness, the Pascal 2021 HW is also ideal for installation into equipment. An oil drain valve simplifies the maintenance in confined spaces.

The single-phase universal motor allows for operation almost everywhere in the world.

The proven service concept of the Pascal series makes maintenance predictable and ensures a constantly high availability. The maintenance intervals can be extended by using different operating fluids.

For more information, contact Pfeiffer Vacuum GmbH, Asslar, Germany Web: www.pfeiffer-vacuum.com.

HYDRA-CELL MT8 Series pumps will deliver positive displacement flows with highly repeatable accuracy so they are ideally suited to metering and dosing applications where precise volumes of liquid are required in a specified time period.

These pumps are designed to handle a variety of processing liquids at low flow rates and high pressures, exceeding API 675 performance standards for steadystate accuracy (±1%), linearity (± 3%) and repeatability (±3%). Electronic flow control increases accuracy and reliability and they are also available with a manual, variable speed gearbox for use in hazardous areas.

Their integral multiple hydraulically actuated diaphragms ensure pulse-free, linear flows across a wide pressure range, without the need for expensive pulsation dampeners. They are also are easy to monitor ensuring simplified control systems.

MT8 pumps are also hermitically sealed which effectively separates the power end from the process fluid which helps to eliminate leaks and the associated risks and hazards along with the expense of seals and packing.

They also have a replenishment valve system in every piston which ensures optimum actuating oil on every stroke resulting in the benefit of continuous accuracy whilst also protecting the pump from damage in the event of a blocked suction line.

The range covers capacities from 0.23 lit/hr up to 30.2 lit/hr at discharge pressures to 241 bar and is available in a choice of wetted materials including PVC, PVDF, 316 stainless steel and Hastelloy C. A duplexing option is also available which enables two MT8 pumps to run at the same flow rate with only one gearbox and one motor, effectively doubling capacity within a smaller footprint and also lower investment cost than conventional metering pumps. For example, two different chemicals can be metered in a precise 1:1 ratio.

More details at: www.michael-smith-engineers.co.uk/products/ hydra-cell/metering-pumps/mt8-triplex-metering-pumps For more information contact Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk Web: www.michael-smith-engineers.co.uk/

December 2018 – Process Industry Informer

17

PUMPS & VALVES

AODD pumps

contribute to safety in mines AODD pumps are the workhorses of the mining industry – and have a key role to play in improving the safety of the mining industry.

What springs to mind when you read the word “mining�?

Probably high on your list is another six- letter word: “safety�. Yes, mining and safety go together like driving and SEAT BELTS 9OU CAN T HAVE ONE WITHOUT THE OTHER /THERWISE you are in big trouble.

Unfortunately it hasn’t always been like that, as a trip back in time clearly illustrates. In 1931 in mines around the world – metals, non-metals and coal – there were an astounding 94,221 accidents, of which 1,688 were fatal.

Thankfully, safety measures in mines have improved beyond recognition since then. However, the industry is far from achieving its goal of zero fatalities and injuries. In 2016, 7,045 accidents were recorded in mines, of which 26 were fatal. (Source: U.S. Mine Safety & Health Administration, updated December 2017).

In mining operations, pumps are pushed to their limits.

Nearly all mining processes occur in extremely harsh, unforgiving conditions. Deep underground, you need equipment that operates reliably and consistently, and that requires minimum maintenance. Step forward the AODD pump!

Thanks to their high reliability, AODD pumps are tasked with handling a wide range of solids, abrasives and particulateridden liquids. It would be impossible to name all possible applications, but some of the major ones are as follows:

It’s tough down there!

A number of design characteristics incorporated into a specific, clamped metal AODD pump contribute to an AODD pump’s reliability and make it a first choice for many of these tasks. High on the list is a shock-absorbing polyurethane screen base. This is perfect for absorbing the impact from solid particles. Another is increased internal clearances to prevent aggregate entrapment, which plays an important role in maximizing pump durability. Yet another feature is an integrated suction strainer that often comes with the option of plumbed suction.

s 2AW MATERIAL TRANSFER s "ULK LIQUID CHEMICAL TRANSFER s /NSITE BULK FUEL TRANSFER s /IL SEPARATION PROCESSES

There are many areas in which mining safety has improved. These range from the adoption of new, safer technologies, improved ventilation, better ground control practices, and more stringent health and safety regulations. Another area focuses on using safe equipment during the exploration and extraction processes.

And here, one significant contribution to safety comes from an unexpected source: the humble air-operated double diaphragm (AODD) pump.

WHAT MAKES THE AODD SO RELIABLE?

s 4RANSFER AND TREATMENT OF MINE TAILINGS s !BOVE AND BELOW GROUND DEWATERING s ,EACHING OF COMMODITY BY PRODUCTS s &ROTH mOTATION FOR PARTICULATE SEPARATION IN SLURRIES s 7ATER RECIRCULATION s 7ASH BAYS FOR LARGE SCALE MACHINERY AND VEHICLES s 7ATER LAND RECLAMATION s 3OAP DISPENSING THROUGH ONSITE BATH HOUSES

HUSKY 1050 One of Graco’s best-selling AODD pumps – and one that is in service with many mining operators all over the world – is the Husky 1050, which is a 1-inch (25.4 mm) AODD pump that is available in aluminum, polypropylene, conductive polypropylene, PVDF, stainless steel and hastelloy. It offers a diaphragm life that is up to five times longer compared to other diaphragm pumps in its class.

Spring loaded, externally serviceable pilot valves ensure fast change-over and low pulsation.

The Husky 1050 is submersible, intrinsically safe (available IN !4%8 CONlGURATION AND LUBE FREE )T CAN RUN DRY AND has outstanding anti-freezing properties. It has a maximum fluid flow of 50 gpm’ (189 l/min), and a maximum fluid discharge pressure of 125 psi (8.6 bar, 0.86 MPa). It is capable of pumping solids of size up to 1/8 inch (3.2 mm), and offers a fluid displacement per cycle of 0.17 g (0.64 liters). It is manufactured according to Quality Management System ISO 9001, Environmental Management System ISO 14001, and Occupational Health and Safety Advisory Services OHSAS

18001 STANDARDS. Thanks to these characteristics, the Husky 1050 AODD pump will operate day in, day out, in the most demanding conditions in the mining industry and in the safest manner possible, for site personnel and the environment.

For more information on the Graco Husky 1050, OR 'RACO S OTHER !/$$ PUMPS CONTACT 7ALTER ,EETEN at walter.leeten@graco.com or visit the Graco webpage at www.graco.com/husky.

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Process Industry Informer – December 2018

December 2018 – Process Industry Informer

19

PUMPS & VALVES

NEW FLUKE MA LOOP VALVE TESTER SPEEDS ASSESSMENTS OF HART SMART CONTROL VALVES WITH BUILT-IN TESTS THAT ENSURE QUICK, RELIABLE RESULTS perform valve tests, while the valve test quickcheck results provide at-a-glance diagnostics to make faster maintenance decisions.

The Fluke 710 features pre-configured valve tests for reliable and repeatable testing. The built-in routines include: s -ANUALLY CHANGING THE M! SIGNAL AND viewing the HART position and pressure variableinformation. s &ULL RANGE RAMPING OF THE M! SIGNAL FROM to 20 to 4 mA while recording the 0-100-0 percent position, or the pressures applied that move the valve from 0-100-0 percent.

The new handheld control valve tester simplifies testing with dedicated tests that perform a quick health check to provide good/ marginal/bad results Control valve testing has meant using complicated testers that require extensive training, the removal of the valve, and often one-to-two hours of test time on the bench.

4HE NEW &LUKE˜ M! ,OOP 6ALVE 4ESTER allows technicians to source the 4-20 mA signal while it interrogates HART data to collect critical information about the valve’s position and status, providing quick checks of control valves while they are in place. With built-in test procedures and an intuitive interface, the Fluke 710 allows technicians to quickly and easily

s 3TEPPING THE M! SIGNAL ON THE INPUT TO THE valve in steps and evaluating the valves response to the mA input changes. s 3PEED TESTS TO DETERMINE HOW FAST THE VALVE can open or close. s "UMP AND PARTIAL STROKE TESTS THAT HELP TEST valves over a portion of their range so they can be tested in a live process.

Test results are stored in the memory of the Fluke 710 where it can be uploaded to the included ValveTrack™ analysis software.

Information about all Fluke products can be obtained via the Fluke web site at www.fluke.co.uk or Tel: 0207 942 0700 E-mail: industrial@uk.fluke.nl

NEXT GENERATION SMART SEVA ACTUATORS FROM BADGER Badger Meter has launched its new, next generation BADGER SMART ELECTRIC VALVE ACTUATOR, available through PUMP ENGINEERING. The SEVA actuator is built with military grade components to withstand extreme conditions while the microprocessor- controlled linear stepper motor gives the accuracy, repeatability and reliability for precise control.

Two models are available with 135Nm (SEVA-100) and 270Nm (SEVA-200) providing torque for Badger Research Control Valves measuring from 1/4� up to 2�. The actuators have options for EtherNet/ IP and ModBus TCPIP / RTU protocols and are certified by the Open DeviceNet Vendors Association (ODVA).

when there is a loss of signal; fully closed, fully open, hold position, or set value. Both the full closed and full open positions are defined during set-up, and the in the event of loss of power, there are five available positions; continue operation, fully closed, fully open, hold position, or set value, plus a SEVA actuators feature a dual-port manual override capability. Flameproof and Industrial Ethernet card and can be set-up via !4%8 %%X D VERSIONS ARE ALSO AVAILABLE the built-in firmware or via a USB port.

The actuators allow for both linear and Device More at: www.badgermeteruk.com/badgerLevel Ring (DLR) network protocols for greater smart-electric-valve-actuator/ feedback for more demanding systems.

For more information contact Pump Engineering Ltd, Littlehampton, West Sussex

The actuators are designed for extreme conditions and provide accuracy of (Âą1% of full scale) for precise positioning applications using a loop-powered feedback signal. They also feature four positions

Tel: 01903 730900 E-mail: chrisn@pumpeng.co.uk Web: www.badgermeteruk.com/

HYDRA-CELL’S SEAL-LESS DESIGN ENSURES HIGH PRESSURE COOLANT EFFICIENCY Hydra-Cell High Pressure Coolant Pumps from Wanner are claimed to be the most energy efficient, machine tool coolant pumps available, measured at upwards of 80%, pump shaft to hydraulic power.

Being true positive displacement pumps, they maintain this exceptional efficiency virtually irrespective of coolant viscosity and system pressure whereas screw and gear pumps, that rely on the pumped coolant for internal sealing, suffer a marked fall-off in efficiency as system pressure increases or fluid viscosity is reduced.

With a Hydra-Cell pump, flow rate is directly proportional to input shaft speed, enabling a variety of accurate control options to be employed.

Of great benefit in metalworking is HydraCell’s ability to handle fines entrained in the coolant that can cause major wear problems in pumps with dynamic seals, have bearings immersed in the pumped coolant or have close internal tolerances to maintain efficiency. With no close internal tolerances, no dynamic seals and no bearings immersed in the coolant, Hydra-Cell pumps are not prone to wear, minimising the need for maintenance and guaranteeing efficiency over a long life.

And as an added bonus, Hydra-Cell pumps are able to run dry indefinitely with no adverse effects‌ a condition that destroys other pumps with dynamic seals‌ filter blocking remains undesirable but thanks

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to Hydra-Cell it is not disastrous. With high pumping efficiency, long service life and minimal maintenance requirement, HydraCell seal-less, coolant pumps can truly be considered to be the high pressure coolant solution with lowest cost of ownership.

For more information contact Wanner International Ltd, Fleet, Hants.

Tel: 01252 816847 E-mail: sales@wannerint.com Web: www.hydra-cell.eu/

Process Industry Informer – December 2018

FEATURED ARTICLE

By Phil Burge

Eliminating

lubricant contamination from food processing machinery

Contamination poses serious problems for food and beverage producers.

As production becomes more and more reliant upon automated machines, there is yet another source of potential contaminants: spilt or leaking lubricants. Phil Burge, Marketing and Communications Manager at SKF describes how food and beverage manufacturers can avoid this problem.

Food and beverage is a major contributor to the UK economy. Early in 2017, the Food and Drink Federation commissioned the global professional services network operator, Grant Thornton, to undertake a study into the UK food and beverage manufacturing sector. Among its findings, the sector manufacturing gross value added (GVA) grew by 27% between 1997 and 2015 (compared with 13% for manufacturing as a whole over this period). In 2017, it accounted for 16% of total manufacturing GVA, making it the largest manufacturing sub-sector in terms of GVA contribution.

Food safety continues to be a major concern for the sector.

In common with other large economic contributors such as the automotive industry, product recalls can have serious business consequences. For food and beverage producers, product recalls arising from contamination events pose a serious threat to profitability, and as the sector grows its investment in automation and high-end processing machinery, so too does the risk of contamination from essential machine lubricants.

The food and beverage industry estimates that between 15 and 25% of its entire maintenance budget is spent as a result of poor lubrication practices. Indeed, as much as 40% of all premature bearing failures in this industry can be tracked down to lubrication problems. While the food and beverage industry has any number of lubrication methods to choose from, not all are recognised under current hazard analysis and critical control points (HACCP) certification scheme, which is widely adopted throughout the industry.

Implementing HACCP compliant lubrication management techniques that are primarily designed to eliminate contamination risk is therefore imperative for any food and beverage manufacturers.

Several technologies have emerged to support HACCP compliant lubrication practices for food and beverage processing machinery containing bearings or transmission chain driven and flat top conveyor systems. This includes re-lubrication-free bearings, fully automated lubrication systems and NSF H1 certified lubricants. In general, the industry adopts three main approaches to avoiding lubricant contamination: the use of ‘food- grade’ lubricants; the use of sealed bearings or a move away from grease lubrication altogether, towards alternative ‘dry’ or ‘solid’ forms of lubricant technology.

Food-grade lubricants are widely used, and are certified for food production punishing, inducing lubricant leakage from bearings and water ingress, both of which will shorten the life of a bearing. Even if a lubricant is food-grade, leakage into a food product is wholly undesirable, so efficiently sealed bearings are commonly used.

December 2018 – Process Industry Informer

Bearings that are required to tolerate frequent wash-downs, such as those used in a poultry processing application, for example, are usually contained within corrosion- resistant composite housings, have stainless steel bearing inserts and a special multi-lip seal that prevents both grease displacement and water ingress. A poultry processing firm that was advised by SKF to use this type of bearing as a replacement for previously installed nickel-plated cast iron bearings, has seen bearing service life effectively quadrupled, with substantial savings made on maintenance and lubricant consumption as a result of the change.

Solid Oil

MANUAL OR AUTOMATIC?

High temperature bearings

So-called ‘dry’ methods of lubrication have proved particularly beneficial to the smooth running of conveyors in baking ovens operating at temperatures of 180°C or higher.

Bearings within ovens require frequent re-lubrication, because the high temperatures can degrade grease very quickly. A solution is to replace traditional grease lubricated bearings in these applications with like-for-like versions that use graphite cages. Here, tiny graphite particles are eroded from the cage and deposited as a thin layer onto the surface of the steel balls. Graphite is a very effective lubricant, and this thin, protective layer is enough to prevent the direct metal-to-metal contact that ultimately shortens bearing life. Although the cage is wearing away gradually, the effect is very slow and will usually last for the life of the bearing.

Reducing the frequency of re-lubrication or eliminating the need for lubrication altogether, and having effective seals that protect against lubricant loss and damaging ingress of contaminants, will go a long way to achieving food safety.

A good example is our Solid Oil encapsulated lubricant technology, which can be applied to virtually any bearing.

This uses a polymer matrix saturated with lubricant that completely fills the internal space, encapsulating the cage and rolling elements and ensuring that food particles are kept out and chemicals and are virtually maintenance- free.

This approach has been successfully applied on a bottle filling station, where previously used stainless steel deep groove ball bearings, although sealed and greased for life, were leaking grease and admitting water during the frequent washdown operations. Replacement our bearings with Solid Oil lubrication had a huge positive effect: bearing service life was extended from 12 weeks to two years, while maintenance costs were slashed and leakage almost completely eliminated.

Manual lubrication in the food and beverage sector raises a number of issues. It is labour-intensive and time-consuming, and imprecise manual metering may lead to over- or underlubrication which will have an impact on machine reliability and the cleanliness of the production environment. Underlubrication is likely to cause leakage of excess grease into the processing environment as bearing seals are compromised and, of course, poor lubrication will ultimately result in the premature wear of bearing rolling elements.

Manual lubrication in food and beverage processing environments will also come up against a number of restrictions due to the nature of the operations and the products being processed. Certainly, there will be strict controls concerning access for personnel during production for reasons of safety and hygiene; the process equipment is also likely to be complex and not all lubrication points will be easy to access, leaving often vital parts of machines poorly lubricated or missed out altogether. An alternative approach is to automate the process of lubrication such that all points receive the marketing correct amount of lubricant, at the appropriate time while avoiding the intervention of maintenance staff.

In essence, an automated lubrication system comprises easily accessible and refillable central reservoirs from where lubricant, oils or greases, are pumped in precisely metered quantities via a system of pipes directly to a machine’s lubrication points.

Automated centralised lubrication systems can be installed at the time of machine installation or retrofitted to existing machines. Examples include our SYSTEM 24 and MultiPoint lubrication systems, which can be mounted for just one or many lubrication points to deliver the right amount of an appropriate lubricant 24 hours a day, seven days a week.

The quantities and timing of automated lubricant deliveries will depend on the severity of duty and/or environmental conditions in the plant, and might follow an existing maintenance schedule that reflects these needs. In more advanced configurations, the lubrication cycle might be based on statistical machine data (such as the number of revolutions or other machine ‘events’), on data from real time condition-based monitoring systems or on the results of lubricant analysis.

While lubrication is absolutely essential to efficient bearing operation, the food processing industry must make every effort to minimise, at best eliminate, the risk of product contamination from bearing lubricants. This means that processors are increasingly looking at alternatives to traditional food-grade grease lubricated sealed bearings, which have proved to mitigate such risks.

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FOOD & BEVERAGES

CAN YOU STRIP AND CLEAN YOUR METERING FEEDER IN LESS THAN 10 MINUTES? – WE CAN! Reducing down-time is always a challenge for any business in the Powder Handling industry.

7HETHER IT S TO CLEAN YOUR MACHINE OR TO MAINTAIN IT THERE S NO OTHER WAY OF LOOKING AT it - stopping production costs money!

the auger screw underneath, which is also instantly removed. The unique design of Trantec’s metering feeders means the shaft seals can also be removed in a matter of seconds, exposing the shafts for easy-cleaning.

Trantec’s Metering Feeders offer optional quick-release, easy-clean features for rapid dis-assembly and re-assembly of your machine.

Our metering feeders, or screw feeders are suited to all industries, particularly Food and Pharmaceutical, as down-time is kept to a minimum when cleaning between batches, essential for avoiding cross-contamination.

Once all parts have been removed, the inside of the machine can be quickly cleaned and a second set of parts can be used to replace them.

All-in-all down-time is kept to under 10 minutes and the used parts can then be placed in the dishwasher for sanitary cleaning. With only one or two moving parts, the auger screw and optional agitator, maintenance is kept to a minimum.

This, along with our advanced design techniques means your metering feeder can run for longer.

The removeable front cover is quickly detached by way of a clip at each side of the machine.

This reveals the inside of the conditioning chamber which houses the independently driven agitator, used for breaking bridges that may form when metering non-free flowing materials.

The agitator can be swiftly removed to reveal

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For more information contact; Trantec Solids Handling Ltd, Tel: +44 (0)1282 777566 Email: sales@trantec.info Web: www.trantec.info

PROSEAL TEST KITCHEN SERVES UP TRAY SEALING PERFECTION Tray sealing specialist Proseal has refurbished and expanded its popular Test Kitchen facility, providing an enhanced service to help food manufacturers identify their ideal tray packaging requirements.

The ProTest machine is a universal, bench-top peel strength testing unit that quantifies the peel strength of any tray and film combination.

This tells users how much force is required to peel open the film –an invaluable tool in ensuring that a pack meets the required peelThe Proseal Test Kitchen offers access to a ability standards that will ensure it offers the wide variety of testing machinery, allowing ideal balance between customer convenience companies to carry outshelf-life trials and seal and food protection. integrity testing in order to facilitate smooth product launches without the need to invest in The Test Kitchen has been designed to provide their own materials and equipment. an ideal environment for food testing with excellent lighting, easy-clean surfaces, and The availability of more than 15,000 trial storage for chilled and frozen products. plates and vast stores of trays and films of different materials in stock for trial samples “The Test Kitchen has already benefitted lots and inspiration allows food producers to of our suppliers and customers by allowing identify the most appropriate solution for them to prove material compatibility, analyse their particular applications. In addition, film tensile strength and produce presentation Proseal can provide expert advice on the samples,” explains Jessie Malone, best packaging suppliers to use for different Test Facility Manager at Proseal. requirements.

For more information contact Among the testing machines in the new facility Proseal UK Ltd, Adlington, Cheshire. are a vacuum tank, gas cylinders for MAP, gas Tel: +44 (0) 1625 856600 analysers and Proseal’s ProTest unit.

Email: info@prosealuk.com Website: www.proseal.com

Process Industry Informer – December 2018

HYGIENIC SEALING FOR FOOD AND BEVERAGE INDUSTRIES Freudenberg Sealing Technologies, a leading global specialist in sealing products and their application, has announced the release of its Hygienic Usit® EHEDG- compliant sealing washers, a secure innovation for all hygienically demanding open processes in the food and beverage sector.

Hygienic Usit availability is via Dichtomatik UK Ltd, the exclusive provider for Freudenberg’s food and beverage related products in the UK. By employing Hygienic Usit sealing washers in combination with special screws and cover nuts, being known under the brand name NovoNox from KIPP Werke, entire screw connections can be achievable in line with hygienic design principles.

As the food and beverage market demands a high level of consistency in product quality, food safety and taste, it does not afford any room for error in the production process.

OPC processes envision the cleaning of all surfaces without the need for disassembly or breakdown of the area.

Hygienic Usit EHEDG-compliant washers from Freudenberg Sealing Technologies comprise a flat metal gasket with a vulcanized trapezoidal elastomer bead that forms a dead-space freeform closure with the screw’s flange seat. Importantly, the hexagonal screw with flange – as well as the flange In addition the elastomer bead can be manufactured from white EPDM 253815, for special demands in the pharmaceutical industry.

The Hygienic Usit® is available from Dichtomatik UK in M4, M5, M6, M8, M10, M12 and M16 sizes. The M4 washer can also be used for M3 screw connections.

For more information contact Freudenberg Sealing Technologies, Dichtomatik UK Ltd, Derby Tel: 01332 524422 Email: fst-food-beverage@dichtomatik.co.uk

December 2018 – Process Industry Informer

23

FEATURED ARTICLE

By Clive Jones, Managing Director of Thermal Fluid Supply and Preventative Management Specialist, Global Heat Transfer.

Preparing FOR A

safety audit

Flight passenger safety procedures are so engrained in our minds that it often feels like there’s no need to review them when we get on a plane. As health and safety becomes second nature to us, do plant managers feel the same about an emergency situation in their facility?

Here, Clive Jones, managing director of thermal fluid supply and preventative management specialist, Global Heat Transfer, explains how plant managers using heat transfer fluid can prepare for a safety audit.

In an environment where employees work in close proximity with potentially hazardous substances, such as thermal fluid, plant managers need to ensure their facility is safe. The best way to reduce risk in these facilities is to adhere to regulations.

Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) and THE %XPLOSIVE !TMOSPHERE $IRECTIVE !4%8 137) outline the mandatory requirements for minimising safety risks and protecting workers from fire and the explosion of flammable materials present at the facility.

WHAT IS A SAFETY AUDIT? A safety audit evaluates the condition of a facility and its practices to help ensure that it meets regulations and reduces any risk of incidents. Facilities with a thermal fluid heat transfer system need a regular audit to report onsite health and safety procedures because of the potentially dangerous substances present.

There is no fail or pass when it comes to a safety audit. The auditors collect information about the facility and its safety procedures.

From this, they make recommendations on how to correct the health and safety programme to comply with legislation.

REGULAR MAINTENANCE As there is no failing an audit, plant managers do not need to prepare.

However, plant managers should consider the main parts of an audit to understand where they should carry out regular maintenance in the facility.

Auditors will base the audit on thermal fluid analysis to determine the condition of the oil. They must draw the sample when the fluid is hot, and the system is closed and circulating to ensure it is representative.

If thermal fluid analysis results show that carbon is present in the fluid, plant managers may be able to restore the quality by carrying out fluid dilution or filtration.

This will help to protect the system, continue production and extend the life of the fluid, while keeping maintenance costs down.

Plant managers can also install a light ends removal kit (LERK) to remove volatile thermal fluid components that can be generated at high operating temperatures.

LERKs can be used on systems of any

December 2018 – Process Industry Informer

size, but it is important that light ends are collected safely in the liquid phase of the system’s condenser and disposed of safely.

As well as fluid analysis, plant managers should regularly check the condition of the pipework, flanged joints, gaskets and seals in the heat transfer system. They also need to check the pressure gauges to ensure that they are giving accurate readings.

Carrying out regular checks will help ensure that any system leaks are spotted early.

Plant managers should also look out for smoking flanges and leaking gaskets, as both are signifiers of a leak. These will all be checked during a safety audit and any faulty equipment will be recorded. This will have a negative impact on the audit results, but if left unmanaged could lead to something more serious, such as a fire or explosion.

PROTECTIVE EQUIPMENT For heat transfer operations to run safely, the system’s insulation needs to be in tact to prevent employees from accidentally coming in to contact with the hot system. Spill kits, which include floor signs, hazard tape, pads, socks and a bin specifically designed for hazardous materials, should be replaced immediately after they have been used to ensure that one is always available in the event of a leak or oil spillage.

General housekeeping is also important.

Prior to a safety audit, plant managers should ensure that the facility is free from clutter. This makes it easier for the auditors to walk around the facility and see the condition of the system.

MANAGING RECORDS Records should be kept up-to-date at all times, as plant managers need quick access to their latest thermal fluid sample results and service audits. Frequent thermal fluid samples should be taken and reported ready for review by the auditor. Best practice for representative sample analysis is at quarterly intervals.

DURING AN AUDIT Many plant managers see a safety audit as a reason to check their heat transfer system and processes but having an efficient preventative maintenance plan that runs year- round should mean that preparation is in fact second nature.

During the audit, the heat transfer system should be running at its normal operating temperature and conditions so that auditors get an accurate representation of the fluid.

An independent company should be appointed to carry out the audit, in order to ensure that the advice they give is impartial.

However, an internal engineer should be present throughout the audit to witness any issues highlighted during the audit.

The safety audit mainly focuses on the condition of the thermal fluid and the main components of the system, including the heater, expansion tank and pipework. The auditor may check the condition of the fluid, as well as how often the company takes samples. They also assess whether the company stocks the right level of top-up heat transfer fluid and whether it is stored correctly.

When inspecting the system itself, the auditor concentrates on the condition of the system components and confirms whether there are any leaks. The auditor also checks that operation instructions for each component are easy to access.

They check the area where parts of the system are housed, particularly the heater.

This includes if the heater is in a separate room and whether it is locked or unlocked.

They also look for where operation instructions are kept and if the plant has an emergency stop and drain down procedure.

The auditors also review the maintenance programme at the facility, primarily how the plant manager tests and maintains the fluid and how the plant manager inspects and maintains the system.

They then check procedures surrounding health and safety – from identifying risks, to managing them and communicating them.

Auditors check how the company trains its staff about risk management and safety procedures to ensure everyone knows how

to safely work with the system and manage the heat transfer fluid better.

WHAT HAPPENS NEXT? Once the auditors have completed their checks, plant managers need to focus their attention on the areas highlighted in the report.

After addressing any issues, plant managers can invite the auditor back to look over any changes. The auditor then checks progress and ensures the relevant regulations are being adhered to.

The best way to ensure safety audits are passed every time is by introducing a preventative maintenance programme.

Regular sampling and visual checks of the system helps manufacturers meet health and safety regulations and prevent the risk of costly breakdowns and hazardous incidents.

Implementation of a continuous maintenance programme, such as Global Heat Transfer’s Thermocare, gives plant managers the reassurance that their facility meets the regulations checked during a safety audit.

Even though we may not pay close attention flight safety procedures, they are there for our benefit. Similarly, plant managers should pay more attention to regulations and audit recommendations when working with dangerous substances such as heat transfer fluid.

Regular thermal fluid analysis and maintenance checks can help plant managers get off to a flying start during an audit.

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FEATURED ARTICLE

By Duncan McPherson, CEO at leading gas engine specification and maintenance services, CooperOstlund

Generating off-grid energy The topic of energy is never far from the business and consumer agenda, and with good reason. Rising prices, uncertainty over supply and a focus on sustainability all mean that an innovative approach is needed. Duncan McPherson, CEO at leading gas engine specification and maintenance services provider, CooperOstlund, explains how generating off-grid energy may provide the solution.

THE CURRENT DILEMMA There’s no getting away from the fact that our energy infrastructure in the UK is inadequate. The National Grid is dated, inefficient and widely considered unfit for purpose.

Demand – especially in peak times – regularly overtakes supply availability.

What’s more, with a ban now announced on coal power generation and an already- heavy reliance on power supplied from overseas countries, we’re clearly unprepared for what the future will bring.

But the consequences of this could be devasting. Companies are already offered financial incentives to stop working when power is in short supply, and blackouts are a real threat, potentially grinding operations to a halt and irreparably damaging reputation with suppliers and customers alike.

The unpredictability of energy prices can also lead to spiralling facilities management costs, hitting a company’s bottom line hard.

DECENTRALISATION AS A SOLUTION Considerable work is already underway to find an effective solution for the future, but a number of techniques are emerging to support industry in the short-term. From peaking plants and on-site energy generation solutions, to blended energy programmes, off-grid generation is quickly becoming the stop-gap. Indeed, it’s predicted that decentralised energy will grow 130% by 2030, representing 14% of the UK’s total generation capacity 1 . And with this growth comes benefits, ecentralised energy, the same study finding that on-site energy generation could help UK businesses save around £33 billion by 2030. Combined heat and power (CHP) and energy from waste are predicted to deliver the greatest savings of £20bn.

As the UK leader in the specification, installation, optimisation and maintenance of gas engines (in particular, CHP) we’re at the forefront of this energy revolution, which is heralding a new era in how businesses are adapting to market and regulatory challenges.

Effectively a mini power station, CHP engines are almost twice as efficient than traditional grid connectivity… and much more secure! By generating both heat and power (in one single process) at the point of consumption, users benefit from lower energy costs compared to sourcing electricity and gas independently from the grid.

Over the past 12 months, we’re experienced a dramatic increase in the number of engines installed nationwide. As well as peaking plant setups (off-grid CHP engines that automatically pump electricity into the grid in times of peak demand), fitting CHP engines in industrial scenarios (to replace mains supply) is becoming popular.

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An example can be seen in one of our recent peaking plant installations which saw three, 2.7MW CHP gas engines installed at a site in rural Derbyshire. Operational since April 2018, the plant is running at optimum efficiency and generating more than 8.1MWeenergy to support the National Grid in times of peak demand.

with potential interruptions to energy supply. The fact that equipment can be planned, procured and installed to take factors such business type, site size and energy requirements into close consideration, means that businesses can tailor their energy provision to precisely meet their needs – not just now, but also for the future.

THE BENEFITS OF OFF-GRID

LOOKING TO THE FUTURE

Financially, the numbers add up. In fact, by turning gas into electricity rather than sourcing power direct from the National Grid, companies can experience significant savings because simultaneously generating both heat and electricity from a single fuel source, is a highly cost-effective alternative to traditional mains supply.

The future of our energy infrastructure is far from clear; however, innovation is providing new and improved ways to generate power without relying on mains electricity and the shortcomings of The National Grid. While a long-term solution is essential, for now, short-term stop-gaps are already revolutionising our energy landscape.

The secret to CHP’s success is this heat element of the process. By using waste heat, CHP plants can reach efficiency ratings of over 80%, compared to UK gas power stations, which range between 49 and 52% and coal-fired plants at around 38% 2 . As the gas network is under less demand, this approach also improves energy security. When it comes to peaking plants, the ability to inject power into the grid in periods of high demand is hugely valuable. Alongside preventing blackouts, this again improves energy security and ensures our national energy demand can be met.

Embracing alternative energies, such as CHP, can offer businesses a real lifeline in these uncertain times. By producing their own off-grid energy, companies can not only ensure that their operations run smoothly, to budget and without interruption, but also that they’re doing all they can to boost their sustainability credentials in the process.

1 Utilyx: Coming 2 Association for Decentralised Energy

Undoubtedly, one of the main benefits of decentralisation is the pricing stability it offers against grid reliance. By self-generating energy and knowing the costs involved, businesses can safeguard themselves against the challenges of unpredictable wholesale power prices or sharp increases in network costs. This subsequently protects the bottom line, and therefore profits, and mitigates the risks associated

Process Industry Informer – December 2018

December 2018 – Process Industry Informer

27

FEATURED ARTICLE

Preventative Maintenance Matters

M

as winter comes calling

artin Geobey, Managing Director, UK & Ireland, at IMI Precision Engineering, outlines how preventative maintenance programmes can help alleviate unforeseen and costly downtime issues as manufacturers get their plants ready for the winter months.

PREVENTATIVE MAINTENANCE CHECKLIST FOR PNEUMATICS To help you, this is a standard preventative maintenance checklist to ensure you are on top of your pneumatic maintenance programme: s #HECK YOUR PISTON ROD HAS NOT BEEN DAMAGED BY material debris, rust or corrosion. s 2EMOVE DEBRIS BUILD UP ON THE PISTON ROD TO PREVENT nose and wiper seals leaking.

The winter months present fresh challenges when it comes to keeping manufacturing plants running and productive.

Busy production periods in the run up to Christmas, reduced maintenance staff numbers as they use up annual leave, and the negative impact of cold and adverse weather conditions on machines and plants, can be a combination that is problematic to manage.

The answer, therefore, to reducing the potential for maintenance-related issues to emerge during winter is to plan.

By planning and implementing a preventative maintenance programme, businesses are able to spot and solve small issues before they have a chance to make a bigger impact.

2. LEARN FROM EXPERIENCE Once a preventative maintenance programme is established, not only will the health and performance of the manufacturing output be enriched, it also sets a solid foundation for an ongoing cycle of continuous improvement.

Insight gained from analysing how important components are performing in different environments; how they react to temperature changes and wear and tear, how they deal with altering workload requirements, can help inform and guide plant operation and enable manufacturing organisations to become even more efficient and productive.

This approach puts less stress on maintenance teams to complete jobs within a short timeframe, and reduces the risk that tasks are not always rectified satisfactorily when rushed reactively.

It can also identify high energy consuming components and provide an intelligence-based opportunity to replace them with more efficient solutions, or even take a holistic view about where energy and cost can be saved through the whole production process.

Preventative maintenance scheduling means that all elements of the production process are under constant review to eradicate instances of unexpected failure.

A prime example is the common use of compressed air as a vital resource for manufacturers.

Manufacturers should approach continual preventative maintenance to optimise operational efficiencies for the long term. Examining three key areas will help them to achieve this.

1. USE DATA FOR INTELLIGENCE-BASED DECISION MAKING With the advent of industrial digital technologies (IDTs), organisations now have access to more information about their components’ health and performance than ever before.

Data from smart, connected products placed within production lines can deliver a real time, highly accurate view for operators when it comes to assessing performance against critical KPIs, and whether remedial action is required before issues occur.

A recent Government report estimated that the use of IDTs could, help reduce machine downtime by between 20 and 30 per cent and reduce plant maintenance costs by between 15 and 25 per cent.

Despite its broad use, it remains one of the most expensive forms of energy with a typical 500 litres/sec unit consuming ÂŁ40,000 of electricity per year. The smallest unidentified and unrectified leak within a compressed air system in an industrial environment will make equipment and production less efficient and significantly increase costs.

Recording the data extracted from components is just half the story. It is using the[ experience for the selection of added value solutions that will make the real difference for manufacturers looking for a competitive edge.

3. ADDED VALUE SUPPORT In the unfortunate event when an issue leads to unplanned downtime, manufacturers should be confident that their supply chain is robust, responsive and quality-led.

Often the need to obtain spare parts quickly, can have a direct impact upon the speed which an issue is sorted, and the total financial cost of downtime.

Making sure your supply chain offers sufficient stock levels, has easy to access technical support and has the back-up of field engineers (if required) can be the ultimate safety net.

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s #HECK PISTON SEALS ARE NOT WORN WHICH WILL LOWERING THE potential thrust generated. s 2EMOVE MOISTURE OR DEBRIS CONTAMINATION FROM CYLINDER barrels that could damage piston seals. s #HECK ALL THE PIVOTS ON CYLINDER MOUNTINGS s )F THE CYLINDER MODEL INCLUDES ADJUSTABLE CUSHIONING IS it functioning to a satisfactory level. s #HECK YOUR POLYCARBONATE BOWL COMPLIES WITH "3 6005:1997. Does it display any cracking or crazing? s )S YOUR AUTO DRAIN STILL WORKING OR LEAKING $OES THE drain present audible leakage? s )S YOUR LUBRICATOR DELIVERING A CORRECT LEVEL OF OIL SUPPLY into the downstream? s $OES YOUR PRESSURE GAUGE STILL MONITOR OUTPUT PRESSURE or is it broken? s )S YOUR lLTER ELEMENT CLEAN ENOUGH TO PREVENT PRESSURE drops? s )S YOUR REGULATOR MAINTAINING OPTIMUM PRESSURE $OES the relief hole display a continuous audible leak when under pressure? s #HECK OPEN EXHAUST PORTS OR BREATHERS ARE COVERED TO prevent ingress of debris and to conform to COSHH requirements. s #HECK UPSTREAM lLTERS ARE NOT RESTRICTING AIR mOW TO valves. s 3OLENOID OPERATORS CAN OFTEN SLOW DOWN WITH AGE n check that the speed of operation is still at optimum levels. s #HECK MECHANICAL OPERATORS FOR GENERAL WEAR AND TEAR Replace if necessary – the consequences of failure can be dangerous! s #HECK EXHAUST PORTS ON VALVES DO NOT PRESENT continuous audible leaks. s 7HILST MACHINES NOT RUNNING LISTEN FOR LEAKS GENERALLY through the whole system.

Building preventative maintenance programmes and planning ahead makes good business sense for manufacturers who want to keep plant performance optimised. Doing so will ensure they can sail through the winter months thanks to highly efficient production capability.

Process Industry Informer – December 2018

TANK CLEANING

FILTRATION SOLUTIONS

SKID MOUNTED FILTRATION SOLUTIONS FOR WATER TREATMENT Amazon Filters is a leading supplier of bespoke skid mounted filtration solutions for process control, building services and municipal water treatment facilities for flow rates up to and exceeding 100 m3 per hour.

SPRAY NOZZLE PEOPLE SUPPORTS THE FOOD INDUSTRY Spray nozzle specialists THE SPRAY PEOPLE GROUP (SNP) has made moves to bolster its support for the UK’s food processing industry. With increased pressure on prices and the ongoing uncertainty over supply due to Brexit, SNP are reconfirming their commitment to supporting UK food producers with advanced spray technology. )VAN :YTYNSKI Marketing Director of SNP comments, “In these uncertain times the last thing our customers need is to have to worry about whether a key component is in stock”. Sometimes a 2 week lead-time is unacceptably long so SNP have taken the followings steps: 1. Improved UK stock levels. This means that high quality stainless steel air atomising and tank cleaning heads are available for next day delivery to UK sites.

2. Improved information. Spray nozzle selection can be complex so a redevelopment of the Food Industry section of SNP’s website has been completed which provides users with a wealth of information on correct nozzle selection for optimal spray set-up.

December 2018 – Process Industry Informer

Improved product range. New products have been added to SNP’s tank cleaning range including the World’s first 360º clog resistant tank cleaner the HydroClaw.

The air atomising range has been extended to include new standard body types making it even easier to swap to SNP’s nozzles.

Ivan confirmed, “Whatever one’s personal views and opinions on Brexit, it’s now clear that UK businesses are in this situation together. The food industry faces more uncertainty than most sectors so our efforts are a small, but important contribution to help our customers.

By ensuring quick and hassle-free supply of key components we will help our fellow UK based businesses to get through these uncertain times”.

As one of Europe’s leading manufacturers of process filtration systems - Amazon Filters has an excellent track record of supplying static and mobile skid mounted filtration systems for the filtration of purified and process water, for desalination plants and for municipal water supply.

Drawing upon in-depth understanding and knowledge of the wide range of water treatment processes, Amazon Filters experts are able to work closely with clients to ascertain critical project parameters including contaminants to be removed, water throughput, serviceability requirements and installation space restrictions.

Using modular filter cartridges and housings, Amazon Filters is able to provide filtration systems that offers enormous flexibility and which can be supplied at relatively short notice. Drawing upon its proprietary SupaPore and SupaPleat pleated and SupaSpun depth filter technologies, Amazon Filters skid mounted filtration systems offer longer life and greater throughputs than competitive systems. In addition, the skid mounted filtration solutions from Amazon Filters enable the use of smaller systems lowering operating costs and for new installations can also provide savings on capital costs.

For further information on a bespoke skid or container-based filtration system to safeguard your water treatment process please visit www.amazonfilters.com/ products/customised-housing-systems/ or contact Amazon Filters on +44-(0)1276-670600 / sales@amazonfilters.co.uk

For more details at: www.spray-nozzle.co.uk/spray-nozzles Or contact: ivan@spray-nozzle.co.uk or Tel: +44 (0) 1273 400092

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FOOD & BEVERAGES

NO EMISSIONS AND FLAMMABLE SOLVENTS New water-miscible bonded coatings for elastomers and O-rings Klüber Lubrication now offers new watermiscible bonded coatings free of flammable solvents for the life-time dry lubrication and pre-start lubrication of special applications. Apart from the well-known benefits of dry lubrication, the new product lines significantly improves the sliding and sealing effect of O-rings due to the reduced permeability to gases and liquids. The new product line complements the product families Klüberplus for easier assembly, Klüberflex for dynamic applications and Klübertop for use in the food sector.

“In O-ring lubrication bonded coatings have to fulfill various tasks, e.g. provide a separation effect, simplify assembly, or withstand dynamic loads like in valve lubrication”, explains Rudolf Zechel, Manager Special Projects at Klüber Lubrication. “Bonded coatings for components in the food and drinking waters sector also have to comply with FDA and drinking water requirements.

Our new product line combines the advantages of our proven bonded coatings with the additional benefit of being free of flammable solvents, which is why no emissions are released during application.”

Bonded coatings used for O-rings offer numerous advantages. O-rings can be separated easily during automated assembly. They ensure a high level of safety as leakage or twisting of O-rings during assembly is prevented and joining forces are reduced. In addition, contamination of materials. sensors due to lubrication can be ruled out. Bonded coatings can also be used for colouring to minimise the risk of confusion with different sizes or materials.

In dynamic applications, dry-lubricated O-rings significantly reduce the friction value and increase the service life of components. This applies to seals subject to several hundred revolutions per minute as well as to low-speed applications such as opening fuel filler caps or operating a bell button. Such applications are efficiently protected from freezing in winter time by using bonded coatings.

For more information contact Klüber Lubrication, Andreas Hasslinger, Germany.

Phone: +49 (0) 89 / 78 76-467 E-mail: andreas.hasslinger@klueber.com

AOAC-RI CERTIFIES HYGIENA ULTRASNAP™ SURFACE ATP TEST

Certification one of only two ATP validations worldwide, demonstrates validity of tests for microbes.

Hygiena, a global leader in rapid food safety and environmental sanitation testing, today announced the AOAC Research Institute, one of the world’s most recognizable product certification organizations, has issued its Performance Tested -ETHOD3- CERTIlCATE TO THE 5LTRA3NAP Surface ATP Test for identifying the possible presence of microbial contamination.

As required for AOAC-RI certification, Hygiena used a third-party laboratory to test the results of UltraSnap on stainless steel surfaces in five food matrices, essentially reproducing a food processing facility.

Hygiena EnSURE and UltraSnap™

ENHANCE STEAM QUALITY WITH NEW HACCP GUIDE s &OOD AND BEVERAGE MANUFACTURERS DO NOT ALWAYS include steam within their HACCP s 9OUR QUICK START GUIDE TO INCLUDING YOUR STEAM system in your HACCP details seven steps to help ensure the quality of your final product is achieved at all times s 'UIDE STRESSES THE IMPORTANCE OF TESTING STEAM as an ingredient, just like any other.

Those concerned with quality within the food and beverage industry will already be very familiar with the concept of Hazard Analysis Critical Control Points (HACCP), though many will be less familiar with including steam within their HACCP approach.

The launch of the new guide aims to provide a stepby-step process to helping facilities managers ensure the quality of their final product is achieved at all times by including steam within HACCP. Authored by Francisco Pedrosa, Regional Clean Steam Specialist at Spirax Sarco, the new quick-start guide aims to offer a helping hand to plant operators in the food and beverage industry in understanding and including steam within their HACCP. Your quick-start guide to including your steam system in your HACCP provides seven easy to follow steps

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for operators to end the overlooking of steam within HACCP-based approaches. Steps include: Identifying critical control points, create monitoring processes, and define verification procedures, among others.

“By including their steam system in a HACCP, plant operators can better maintain, and feel more confident about, the quality of their plants output.” says Francisco.

“This guide aims to help those operators ensure that the quality of their final product is achieved at all times – reducing waste and energy costs”.

“All too often I find myself speaking with plant operators at food processing plants who know that they should be including steam within their HACCP approach but lack the knowledge to do so. It is my hope that this guide will help to mitigate the likelihood of physical, chemical, and biological hazards within the food industry and to create a manufacturing sector that places the proactive management of steam quality and food safety at its core”.

To see how you can enhance steam quality, download the quick-start guide here: sxscom.uk/HACCPQuickStartGuide

The test results showed very low limits of detection (down to 0.77 relative light units {RLU}, the measure generated by ATP-based luminometers). The results also showed that UltraSnap was able to detect ATP from surface soiled by food and beverages, at dilutions of 1:1,000 or lower. The UltraSnap was shown to be highly selective for ATP, stable and consistent, and to have no statistically significant variability.

The validation marks the first of Hygiena’s ATP-based test products, and only the second ATP monitoring device, to receive an AOAC certification.

We are delighted that the most used ATP system around the world has been verified and validated for its accuracy and sensitivity by the AOAC,” said Steven Nason, Chief Executive Officer of Hygiena. “This validation is helpful for certain customers and government bodies around the world and validates the claims we have been making on the system for years. ATP testing is the fastest and most effective way for food processing facilities to determine cleanliness levels and accurately identify areas that need attention before food is processed which helps keep our food supply safer.”

To find out more about the EnSURE™ quality monitoring system visit: www.hygiena.com/ultrasnap-food-andbeverage.htm To find out more about the UltraSnap™ Surface ATP test visit: www.hygiena.com/ensure-food-andbeverage-processors.html For more information contact Camarillo, Watford, Herts Tel: +44 (0)7534 613974 E-mail: komal@hygiena.com

Process Industry Informer – December 2018

December 2018 – Process Industry Informer

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