Case Study

Project: Inspection and Repair of 2 Large Infant Formula Spray Dryers (13m diameter x 20m high)

Location: Ho Chi Minh City, Vietnam

In May 2023, Bioscan completed the inspection and repair of two of the largest infant formula spray dryers in South-East Asia in only a 5-day shutdown window.

Above photo shows the inspection of the roof being performed

As the access into the dryers was extremely complex and Bioscan could not use their gantry platform, we decided that the best method would be using rope access. 3 Rope Access Technicians were deployed to the site and a 100% inspection was performed on each dryer, which lasted a total of 5 days. This included the setup and removal of the rope systems, inspection, repair and polishing of 10 defects.

Above photo shows a repair in the roof being performed

The client had been previously required to use scaffolding for these dryer inspections, which required a total of 2 weeks. Bioscan was therefore able to significantly reduce the client’s shutdown time by almost 10 days, therefore allowing for substantial cost savings and huge increase in their productivity of infant formula. Also, without Bioscan needing to use scaffolding, there was no introduction of wooden materials into the dryer and the risk of damage from the scaffolding installation/removal was eliminated.

Above photo shows the inspection of the cone being performed

Utilising Bioscan’s expertise and electronic inspection technology, combined with rope access methods to locate all types of visual and non-visual defects, the client was extremely satisfied in knowing they could continue production of their high care infant formula products in safe conditions.

To find out more about our services and experience, you can explore our website or reach out to us at sales@bioscanltd.co.uk

All inspection methods (visual, cameras, robots, or dye) have their place in the food and beverage industry. But none are as effective at detecting hidden and non-visual defects as Bioscan’s electronic inspection technology.

A case study

In October 2020, Bioscan was contacted by a client who believed they had potential cross-contamination issues arising from a spray dryer. The client had already performed several internal visual and dye penetrant inspections to try and identify possible defects but were unsuccessful.

After setting up Bioscan’s access equipment, our expert inspection technicians began to locate areas of potential concern. They quickly established that in the lower cone of the spray dryer, there were many defects. These were faults that could only be identified by Bioscan’s electronic inspection device; they would not have been detected by visual, camera, robot, or dye penetrant methods.

The images below show two of the areas where Bioscan’s technicians discovered there was a serious concern, as audio and visual feedback from the electronic inspection device were consistent. However, no defects were currently visible to the eye, only the product residues covering the surface.

In total there were around 5m² of areas with potential defects, both in the spray dryer’s weld seams and the sheet metal itself. After discussing the situation with the client, Bioscan’s team then lightly polished these areas to reveal the extent of the damage. The images below show the extremely porous corrosion pitting and cracking, and the likely cause of the client’s cross-contamination issues.

Below are some microscopic images of these areas, to show the client the product residues building up inside the defects during production cycles.

Due to the extent of the damage that the corrosion pitting and cracking had caused to the parent material of the stainless steel, these areas were unrepairable. But the client now had the knowledge of where the likely cause of the cross-contamination was coming from and could plan ahead for the corrective actions.

Without Bioscan’s expertise and electronic inspection technology offering the ability to locate these hidden, non-visual defects beneath the surface of the product residues, the client would have continued to run the risk of producing their food products in unsafe conditions.

To find out more about our services and experience, you can explore our website or reach out to us at sales@bioscanltd.co.uk