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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Vitenam Case Study

Inspection & Repair of Infant Formula Spray Dryers: Vietnam 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.

Inspection of Roof Performed at VietnamAbove 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.

Inspection & Repair at VietnamAbove 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.

Inspection of Cone Performed at VietnamAbove 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

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