Author Archives: Samuel Peppin - Managing Director at Bioscan Ltd

Bioscan’s electronic testing technology is a non-destructive integrity inspection methodology used to inspect the internal surface integrity of industrial spray dryers. Bioscan utilises this inspection technology to electronically detect different defaults within the stainless steel, such as; cracks, incomplete welds (lines or spots), cavities caused by corrosion, porosities, and other defects.

Bioscan’s electronic testing technology has several advantages over other testing methods, which make it a viable alternative. Bioscan’s electronic technology helps manufacturers of food and pharmaceutical products to accurately detect cracks and defects. Being a non-destructive testing method, various industry professionals prefer electronic testing. Electronic testing provides the most accurate results, even when compared to other non-destructive testing methods like visual inspection or dye testing. Continue reading this blog as we delve deeper into the importance and benefits surrounding electronic integrity testing technology.

A] Importance Of Integrity Inspection In Spray Dryers

Spray dryers are a crucial part of many industrial processes across food and pharmaceutical manufacturing. They are subjected to mechanical and chemical impacts, moisture, and dynamic temperatures, which affect their structural integrity. A spray dryer can face various integrity issues, such as cracks, corrosion, pores, and bacterial growth. These issues can be very expensive and time-consuming to fix and affect product safety, leading to cross-contamination risks.

Many of the integrity and safety issues can be addressed early and even prevented with regular spray dryer crack testing. Regular testing can identify cracks and defects early and employ preventive maintenance to avoid extended downtimes. Preventative maintenance can be replacing certain areas of the metal, repairing complex defects or complete replacement of the asset.

B] Benefits Of Bioscan’s Electronic Testing Technology For Spray Dryer Integrity Inspection

1. High Accuracy

Bioscan’s electronic testing detects cracks with very high levels of accuracy. It can detect the smallest of cracks and the slightest of defects. The testing devices are so accurate that they can differentiate between actual defects and minor scratches. This accuracy allows Bioscan’s experts to focus on the crucial defects within the spray dryer. The testing process happens in real-time, so repairs and maintenance can be started immediately to ensure minimum downtime disruption and the safety of the assets once back in production.

2. Non-Visible Defect Detection

Many non-destructive testing methods, like dye penetrant and visual methods, cannot provide an accurate assessment of non-visible defects. Electronic testing methods can accurately detect non-visible defects, such as corrosion, internal pores, and small fine cracks. Discovering and repairing such defects early can help in risk mitigation and reduce downtime.

3. Environmentally Friendly

Unlike dye testing, Bioscan’s electronic testing does not require any additional invasive particles/chemicals. This reduces the risk of contamination and hence, eliminates the need for extensive cleaning and disposal processes. The eco-friendly nature of electronic testing makes it a preferred choice for spray dryer testing.

C] How Does Bioscan’s Electronic Testing Technology Perform Integrity Inspection of Spray Dryers in the Manufacturing Industry?

Bioscan uses the state of the art electronic testing technology to detect even the smallest of cracks and defects without any chemicals or dyes. Our technology covers the entire surface of the spray dryers and can detect defects at a depth between 0.25mm and 5mm.

To conduct a comprehensive inspection, a controlled electrical current is induced into the surface of the material at a high frequency. The surface material is usually made from stainless steel, which interacts with the current and sends the signals back. The response is measured using a device which shows the variation in conductivity, structure, and integrity of the spray dryer surface. The variation is measured to detect the sub-surface flaws in the equipment.

Bioscan’s system is made up of two control units:

• A multi-channel scanning unit which allows a fast analysis of large surface areas.
• And a single-channel probe, which enables the inspector to scan the small surfaces and hard access areas such as angles, and details of connecting pipes and sheet steels.

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

Conclusion

Bioscan offers electronic testing technology to evaluate cracks and structural defects in industrial spray dryers with precision. Regular spray dryer inspections can help to minimise downtime and increase the safety of the final product being manufactured. 

Bioscan’s electronic testing technology offers highly accurate results and can detect even the smallest of defects which may not be picked up by other methods. Moreover, the electronic method doesn’t use harsh chemicals, it is environmentally friendly and doesn’t affect the integrity of the structure. You can improve your spray dryer testing process by adopting electronic testing technology. Feel free to contact us for more information, our experts are always available to help you!

Working at height is often commonly associated with occupational injuries and in worst cases mortality. The risks of working at height include falling, loss of balance, lack of training, and an unsteady or fragile working platform.

Various inspection work in the food and beverage industry such as spray dryer inspections, silo & tanks inspections, and in other industries such as wind turbine inspections, require accessing elevated locations. Implementing effective safety measures for minimising the risk is paramount for avoiding accidents and fatalities.

It is important to understand the risks associated with these inspection works and implement corrective risk management measures.

A] Understanding The Hazards Of Working At Heights

Structures at an elevated height can have many defaults and defects due to negligence. Consequently, workers perform inspection works such as structural inspections, safety inspections of equipment, bridges and platforms, powerline inspection and visual inspections.

Common hazards and risks involved with inspection work at heights:

• Incorrect setting up of the ladder.
• Loss of balance by placing too much weight on the ladder.
• Not checking the protective gear before climbing.
• Lack of training, familiarity and experience on the part of the inspection worker.
• Fragile platforms, bridges and roofs.
• Bad weather conditions.

These risks should be avoided with proper equipment, safety protocols and control measures for working at height, to reduce the chances of injuries and accidents.

B] Key Control Measures for Working at Height Safety

1. Importance Of Risk Assessment And Planning

Conducting a thorough risk assessment to identify potential hazards when working at height can significantly reduce the risk of injuries and mishaps. The inspection process should be well-planned in advance and supervised by professionals. The person conducting an inspection should be trained and experienced. A permit-to-work system can help ensure a formal authorization of the work.

2. Protective Equipment For Working At Heights

Proper protective equipment for working at height is essential for avoiding injuries in case of an unfortunate event. Personal protective equipment (PPE), hard hats, safety glasses, non-slip protective footwear and gloves are the basic safety requirements. Additionally, fall prevention systems such as safety nets, working platforms and harnesses and lanyards are crucial for ensuring safety.

3. Training And Competence Requirements For Workers

An untrained and inexperienced worker may engage in unsafe work practices during the inspection process, raising the accident risks. With a lack of awareness about safety practices, the worker may not use the safety equipment properly, or at all.

4. Emergency Procedures And Rescue Planning

By having an emergency procedure and rescue planning in place, organisations can ensure the safety of the employee. Having clear communication systems and an emergency evacuation plan can help the worker get out of a risky situation. It is important to have an experienced supervisor who can help the worker get down safely if something goes wrong.

5. Safety Culture And Communication On-Site

For any inspection work, the emphasis should be on the worker’s safety. The organisation should focus on safety training, equipment education and hazard recognition. Organisations should make workers aware of various risks and encourage workers to report them to the supervisor so proper repairs can be made.

6. Regular Equipment Inspections And Maintenance

It is important to regularly check and maintain the climbing equipment for ensuring safe working height. The supervisor should test the locks, ropes, connectors and also the platform. The equipment should meet the safety guidelines and be of excellent quality.

C] Mitigating Risks And Hazards In Inspection Work

Inspection workers in charge of performing the task are at the highest risk of injury. First and foremost, the worker must be trained to identify potentially hazardous environments and take proper control measures to correct them.

Control measures for specific hazards in inspection work at heights:

• Ensure working platforms are correctly assembled.
• Plan for evacuation and rescue during emergency situations.
• The worker should be trained, experienced and competent.
• Ensure a safety team is on hand for rescue operations

Proper use of an access gantry can ensure a safe crack testing inspection of spray dryers. To learn more about crack testing and inspection, refer to Bioscan’s spray dryer inspections service page.

D] Industrial Rope Access: A Safe Method For Working At Heights

One of the safest methods of working at heights is IRATA International’s rope access system. It uses ropes and other related equipment to gain access to the inspection level. Rope access methods offer many benefits over scaffolding methods, such as cost-efficiency, time-saving and most importantly increased safety.

Bioscan uses high-quality equipment to ensure safety of the rope access technicians. This equipment includes certified harnesses, ropes, descenders, ascenders, connectors, anchor devices, helmets, and safety glasses.

Ensuring Safety in Rope Access Work:

• Training and certification for rope access technicians: The rope technicians must be well-trained, certified and competent.
• Supervision and monitoring during rope access operations: Having a supervisor keeping an eye on the technician and guiding them through the inspection process.
• Quality assurance and equipment inspection: The equipment should be regularly inspected and maintained well.

Further Read: Gas Detection to Enter Confined Spaces Safely

Conclusion

Working at height poses many risks when using inadequate equipment, untrained and incompetent personnel. Organisations can avoid accidents and ensure safety by providing appropriate training, well-maintained equipment, and expert supervision.

Experience accurate and reliable crack testing inspections of your spray dryers, silos and other process vessels, all performed safely at height by Bioscan! Discover the difference Bioscan brings to your operations. Contact us today and unlock the full potential of Bioscan for your business needs.