Enhancing Operational Safety In Confined Production Zones Bioscan's Approach

Enhancing Operational Safety within Confined Production Equipment

Confined production equipment have become the integral for the manufacturing of complex and sensitive products, especially in the pharmaceutical, chemical, and food sectors. These critical equipments can present significant risks to safety and product quality. This case study examines how Bioscan, a leader in electromagnetic “crack testing” without chemical penetrants, has revolutionized how companies ensure operational safety in these complex and demanding environments.

Problem Statement

Effectively managing operational safety in confined production equipments is a major concern for companies focused on consumer safety and regulatory compliance. Specific challenges include early detection of defects and potential cracks, minimizing unplanned downtime, and preserving product quality in demanding working conditions.

Bioscan’s Solution

Bioscan offers an innovative solution that involves the application of electromagnetic technology for equipment inspection within confined spaces. Unlike traditional methods involving the use of chemical penetrants, this non- destructive approach is environmentally friendly and offers a high sensitivity for crack detection, while minimizing operational disruptions.

Implementation

The implementation of Bioscan’s technology involves meticulous planning regular inspections. This planning optimizes preventive maintenance, while reducing unplanned downtime. The non-destructive and rapid approach allows real-time analysis of critical equipment, helping companies anticipate potential issues.

Agropur Canada Equipment Bioscan Inspection

Implementation of Controls and Certification

In addition to the application of our innovative electromagnetic technology, Bioscan places paramount importance on quality and compliance. All our equipment and processes undergo rigorous controls and are certified to the industry’s strictest standards. 

This certification not only ensures the reliability of our services, but also the safety of our clients. It attests to our commitment to operational excellence and regulatory compliance, which is crucial when operating in sensitive environments. 

Results

Companies that have adopted this approach have seen a significant improvement in operational safety. Early defect detection has significantly reduced the risk of contamination and major failures, thereby preserving product safety. Moreover, unplanned downtime has been significantly minimized, contributing to maintaining productivity and product quality at optimal levels. 

Client Testimonial

Testimonials from our client attest to the effectiveness of this solution:

Client Testimonial

Conclusion

Operational safety within confined space production equipment remains a major concern in the industry. Bioscan, with its innovative electromagnetic technology, is committed to helping companies effectively and environmentally responsibly address this challenge. Our approach not only preserves the end consumers safety, but also ensures product quality, strengthening the reputation and regulatory compliance of our clients. 

To discuss how Bioscan can help you optimize downtime, please contact us today or send an email to sales@bioscanltd.co.uk.

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Bioscan Case Study Minimal Disruption

How Bioscan’s access platform enabled major repair works with minimal disruption

Challenge : Large Scale Repair Works With Minimal Downtime Disruption

Bioscan recently assisted a client in October 2023 with some major repair works to their spray drying chamber alongside the assistance of our access platform and expert technicians.

Spray Dryer Chamber Repair Work Bioscan

Spray Dryer Chamber Ongoing Repair Work

This is where utilising Bioscan’s access platform was discussed, meaning that no scaffolding was required to be installed inside the dryer. After initial setup of the platform which took 4 hours, the repair works could begin. As seen in the photos large sheets were cut out and replaced with ease from careful planning of the operation from the inside and outside of the drying chamber.

Spray Dryer Chamber Outside Working Area

Once the repair works were complete, Bioscan performed a final check of the welds and removed the platform. This saved the client approximately 4 days of production downtime from not requiring scaffolding.

Spray Dryer Chamber New Sheet Installation

This method can also be applied to other large scale projects within spray dryers such as sonic

horn, hammer, nozzles, fire suppression installation, modifications and removals.

To discuss how Bioscan can help you optimize downtime, please contact us today or send an email to sales@bioscanltd.co.uk.

Further Read: Inspection & Repair of Infant Formula Spray Dryers: Vietnam Case Study

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Reactive vs Preventive Maintenance in Manufacturing Industry

Reactive Maintenance vs. Preventive Maintenance

Maintenance of equipment is an important aspect of the manufacturing industry which cannot be overlooked since it ensures smooth operations and extends the lifespan of the equipment.  An unexpected failure can lead to costly downtime and interrupt the production schedule. Therefore regular maintenance is important to prevent such unexpected equipment failures. There are different types of maintenance strategies that companies can adopt, including reactive and preventive maintenance.

Reactive maintenance involves taking measures once the equipment is broken and then repairing them to make the equipment able to work as normal as before. In contrast, preventive maintenance is focused on equipment issues in advance and taking steps to prevent them.

What Is Reactive Maintenance?

Also known as “Run to Failure,” this maintenance approach occurs when the equipment is already broken, and necessary measures must be taken. In this method, there are no prior annual or monthly inspections of the machine. Maintenance is only carried out once the machine is fully exhausted to restore the asset to normal operation.

Although reactive maintenance is not the most effective maintenance strategy, it has some advantages that make it a viable option for some companies. Here are some advantages of reactive maintenance:

1. Lower Initial Costs

Reactive maintenance initially saves money on upfront preventive maintenance and labour expenses. However, relying only on it and neglecting preventive maintenance can harm your business in the long term.

2. Minimal Planning

A reactive maintenance strategy doesn’t require any planning as the equipment is serviced only when there is a failure. 

3. Easy To Understand

This maintenance plan is a simple process as the individual has to react only when there is an equipment failure.

As every coin has two sides, reactive maintenance also has some disadvantages:

1. Higher Repair Costs

As equipment failures are often unpredictable, diagnosing the issue and finding spare parts may not be immediately accessible. Additionally, emergency repairs tend to be more costly than planned maintenance, which significantly increases the expense of reactive maintenance.

2. Lower Production Availability

Reactive maintenance can decrease production availability because equipment failures are typically unpredictable, and identifying their root causes can be challenging. This leads to lower capacity of production and lower profits.

3. Higher Downtime

Since the equipment failure is usually random, finding the root cause can be time-consuming. Shut-downs often happen at peak times, when a system or machine is working flat out, and that can cause all sorts of expenses around business interruption.

What Is Preventive Maintenance?

This involves, performing regular, planned preventive maintenance activities to prevent unexpected equipment failures and downtime. The goal of preventive maintenance is to keep equipment in optimal condition and reduce the risk of accidents.

Here are a few advantages of preventive maintenance:

1. Increased Efficiency

By ensuring that equipment is regularly serviced and maintained, preventive maintenance helps keep the machinery in optimal condition, reducing the chances of unexpected breakdowns and downtime, which ultimately leads to improved productivity and cost savings.

2. Cost Savings

Preventive maintenance service saves you money by detecting and fixing the issues before they get too serious and expensive to deal with. It also cuts down on expensive emergency fixes and replacement parts.

3. Increased Equipment Lifespan

Preventive maintenance helps to extend the lifespan of equipment By keeping the equipment in optimal condition, preventive maintenance reduces the risk of unexpected breakdowns and increases the lifespan.

Preventive maintenance comes with specific challenges. They include:

1. Continuous Training

To effectively manage maintenance work, technicians or employees should be provided with sufficient on-site training. This may result in increased costs and require a labour-intensive approach, requiring an ample workforce to perform maintenance tasks.

2. Scheduled Downtime

Proper planning needs to be done before shutdown to provide the space and equipment access to the maintenance team so that they can perform routine cleaning and repairs. 

3. Higher Costs

Your maintenance team will be performing regular checks and minor repairs frequently to maximise the output. This would result in higher costs combining both labour and materials. 

Why Choose or Transition to Preventive Maintenance?

Preventive maintenance is a proactive approach that helps you identify and address potential issues before they become critical problems. With preventive maintenance, you can focus on the reliability of the equipment with regular inspections and maintenance ensuring that your equipment is in optimal condition. As with regular maintenance, you can avoid expensive emergency repairs and predictability allows you to schedule maintenance in advance.

Choose Bioscan For Your Preventive Maintenance Inspection

At Bioscan, we detect cracks and other defects within the equipment that could compromise product quality of the finished product, in stainless steel pressure and non-pressure vessels. Using advanced technology, we not only detect these issues but also measure crack depths and assess material thickness to identify weak spots. To minimize the damage that major cracking can create, we recommend carrying out preventive maintenance inspections frequently so that corrective action can be taken beforehand. 

An instance of prioritizing preventive maintenance took place in 2021 when one of our long-standing clients reached out for our services. During our thorough examination of their equipment, including spray dryers and other vessels, we found severe stress corrosion cracking in the weld seams. Unfortunately, rectifying these cracks required replacing the affected metal, requiring an extended shutdown.

Additionally, in our 2021 inspection we found an additional 50 cracks compared to the 15 defects addressed during our 2016 inspection. More frequent inspections could have fixed the problem early or been better managed with yearly checks.

Check Here for a detailed Case Study:  Determining the Frequency of Preventative Maintenance Inspections

Our global services are easily accessible – you can have our access equipment shipped directly to your plant. Alternatively, for a cost-effective approach, you can purchase the equipment from us and store it at your facility.

When you’re ready for testing, our dedicated technicians will be available at your location to conduct the tests for you. Feel free to contact us, if you are planning to carry out the preventive maintenance checks. You can also email us at sales@bioscanltd.co.uk to learn more about our services.

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