Automation technology increases lost product recovery for meat processing plant

Problem

 A Midwest beef processing facility had a dissolved air flotation system that could not consistently recover the necessary level of FOG from the wastewater stream. One to two pounds of oil and grease per animal was escaping the plant and contaminating a wastewater lagoon.

Solution

 The company deployed S.sensing CS technology from Kurita America. The approach included injecting chemistry through an intelligent system that continually records wastewater loading and flow. It also adjusts chemical injection volume instantaneously on the front end of the DAF system based on those variables. The Kurita team determined the exact proportion of coagulant, flocculant and pH control to achieve the optimum FOG recovery. Then they programmed the unit to automatically adjust coagulant and flocculant injection.

Result: 

The technology increased recovery, providing two more pounds of marketable oil and grease per animal and resulting in a cleaner and healthier wastewater lagoon. The revenue gain amounted to more than $400,000 per year. 866-663-7632; www.kuritaamerica.com

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Solution needed for flushables becoming entangled in impellers

Problem

 Rags and so-called “flushable” wipes were getting tangled in the impellers of the pumps in a Maryland sewage lift station. Operators diagnosed pump condition by monitoring suction and discharge pressure, so every pump required a gauge. However, gauges, transmitters and pressure switches were affected by solids in the wastewater. Diaphragm seals bought time, but the suspended solids gradually became impacted under the diaphragm, and the gauges became frozen at one point on the dial.

Solution

 The facility installed Isolation Rings from Onyx Valve, consisting of a steel ring with a rubber inner tube filled with silicone oil. Pressure in the wastewater stream presses against the inner tube, which transmits the pressure to the silicone oil. The pressure impulse travels up through the steel ring and into the pressure gauge. The only fluid in the gauge is clean clear silicone oil.

Result: 

The entire assembly nests between flanges and provides a full round unobstructed flow path, guaranteed never to clog or plug. It has performed flawlessly. 856-829-2888; www.onyxvalve.com

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System ensures quality, increases production, and reduces chemical usage

Problem

 A large manufacturer of residential HVAC systems experienced water spotting and increased chemical consumption in a powder coating operation as production increased.

Solution

 Electroplating Consultants International proposed four interventions, including counterflowing rinse water and at-tank continuous monitoring of water conditions using a Myron L water quality management system. ECI installed 900 Series Monitor/Controllers for all five stages of the pretreatment process because of their accuracy, multiparameter capability and the service Myron L had provided on their 720 system. The 900 Series communicates the status of pH, conductivity/TDS, and temperature real time. At Stage 4, chemical feed is controlled using variations in pH values. The manufacturer uses the handheld 6PFCE-BD to validate the performance. Variation between the two instruments does not exceed 0.1 pH on Stage 4 and 25 ppm TDS on Stage 5. The company also deployed a heavy-duty pH probe from Myron L that resists hydrofluoric acid in the coating chemistry.

Result: 

The manufacturer stabilized its pretreatment chemical processes and cut Stage 4 chemical consumption in half. Part density on the line increased by 25% as the racks went from 5- to 4-foot centers. Line speed increased from 20 to 25 feet per minute. Overall production throughput increased by more than 25%. 760-438-2021; www.myronl.com