Case study: Manufacturing Efficiency
Process
This case study relates to EFS’s work with a leading manufacturer of aquacultural fish feed where the main process involved grinding of raw materials for extrusion. We were contacted to identify and implement efficiency improvements and help the manufacturing team to reduce costs and disruption arising from unplanned down time.
Substance Type: Mixed process minerals and feeds
Problems / Issues
- Activated carbon filter blinding due to excessive dust emissions being released from the grinder filter
- Costly replacement of the activated carbon – estimated £25,000 per change every 8-12 months
- Replacing new filter bags within the grinder systems every 8-12 months
- Limited performance of grinder output due to restricted airflow
- Regular unwanted down time of plant
- Environmental impact due to poor carbon odour absorption and dust emissions to atmosphere
Images of situation before EFS improvements :
Solutions / Improvements
- Change the fitting seal of the filter bags from a push clamp to snap band
- New filter cages and bags to ensure the correct bag to cage fit for better cleaning
- Enhance the filter media more efficient capture of sub-micron dusts and better on surface cake release
- Replace all damaged solenoids and gaskets for optimal pulse cleaning
- Regular preventive planned maintenance system to check all function cleaning equipment and spot check the filter clean side chamber
Images of results after EFS improvements :
Results
- CTC (butane) testing of the carbon indicates that there is more an absorption rate within the carbon over the 12-month period than before
- Current filter bags are still preforming at a low pressure drop of 80mm WG after 2 years of operation
- Spot check on the clean side chamber shows no visual signs of dust containment
- Stack sampling indicates that the dust particle levels within the stack are well below the site permit levels
