The Client
Enviro Technology Services Ltd were approached in 2024 by Microferm, an additives manufacturer, to provide an effective solution for monitoring and reporting emissions to air from their dust collectors.
Overview
The food ingredient industry is an inherently dusty business; fine particles require highly efficient dust collectors to reduce both costly product loss and the presence of fine particles within the plant, which could pose serious risks to health and safety. This case study describes the successful installation of a new dust probe system, which the client notes has been invaluable in removing the need for an expensive service agreement. The decision to choose Enviro Technology Services Ltd was based on a reputation within the industry.
The Challenge
The client, an additives manufacturer operating in the food ingredient industry, faced the challenge of ensuring that their dust collectors were highly efficient in maintaining a safe working environment and minimising product loss.
Their dust collectors relied on filter cartridges that are prone to wear and tear, making them susceptible to sudden bursts. A burst can lead to unplanned downtime, costly repairs, and potential environmental compliance violations. Frequent service visits can be expensive, and recurring costs associated with maintenance prompted the search for a more reliable and self-sufficient monitoring system.
To address these issues, the client required a user-friendly and cost-effective solution, that could provide an early warning in the event of a filter cartridges burst, along with the capability for trend analysis to support environmental reporting.
Solution
ET recommended that the client should install the Sintrol S203 Full Display Dust Monitor at their facility, with the capability to install wireless GSM technology in the future.
The Sintrol S203 is a continuous trend monitor that allows the client to observe the performance of filtration systems and ducts over a period of time. The S203 is perfect for installation after any filtration system or in common line channels leading into emissions points of a plant.
The S203 monitor is both convenient and reliable as it has an easy-to-use auto-setup feature that takes less than 30 minutes from installation. A modern Inductive Electrification principle minimises the need for maintenance on the dust monitor and provides an accurate trend for end users.
Client benefits
- A new dust probe system to help develop a healthier plant environment
- Easy monitoring of dust collector site operations
- The new system was installed complete with an audible and visual alarm alert providing early warning critical alarm indications
- The new system eliminated the need for highly expensive emergency shutdowns
- Improved maintenance efficiency
- Bag filter performance monitoring to prevent product loss and increase health and safety (with predictive cartridges leak).
Conclusion
The new system was installed complete with an audible and visual alarm alert. The ability to continuously monitor collector performance and events has all but eliminated the need for emergency shutdowns while improving maintenance efficiency.
The facility plans to “daisy-chain” a further five dust probes in the system with two further dust monitors integrated into the existing control panel.
According to the Engineering Manager, the new system has been invaluable in removing the need for an expensive service agreement.
