Author Archives: Samuel Peppin - Managing Director at Bioscan Ltd

Silos and storage tanks hold raw materials, process inputs, and finished products, and most days they simply do their job. That reliability makes it easy to overlook their condition until something visibly goes wrong. By the time it becomes a problem, the consequences could range from compromising the safety of the operation, the quality of products, or delays in schedules. Constant loading, moisture, temperature changes, chemical exposure, etc., can cause cracking, corrosion, deformation, and connection damage over time. Getting familiar with early warnings can enable plants to stay ahead of the issues. This guide covers seven signs your tank may need attention, when to schedule an inspection, and how tank integrity inspection services give a clearer picture than routine observation alone.

Why Regular Silo and Storage Tank Inspection Matters

Inspection works best as part of ongoing asset maintenance, not as a reaction to a visible failure. Storage assets face constant stress from fill and discharge cycles, abrasion, moisture, and the materials they contain. This pressure erodes the structure in a gradual manner, and any early damage that occurs may go unnoticed. Using a systematic method of inspection ensures that the facility is able to learn how the asset is ageing, and it becomes easier to spot any problem before it develops into something bigger.

7 Signs Your Silo or Storage Tank May Need an Inspection

Visible Cracks or Surface Damage

Cracks, dents, and surface damage should not be treated as cosmetic. They can point to structural stress or material fatigue that is not obvious from the outside. Small defects can grow over time, so they are worth examining early.

Corrosion or Rust

Rust patches, peeling coatings, and discolouration often signal material degradation. Corrosion can weaken walls and fittings gradually, and the surface may show only part of the damage.

Leakage or Unusual Moisture

Unexpected dampness, seepage, or material escaping from a tank can indicate a breach somewhere in the containment. Even a small amount of leakage should be investigated and resolved to ensure safety or prevent product loss.

Deformation or Changes in Shape

Bulging, distortion, or settlement can indicate an underlying structural or foundation issue. A tank that no longer holds its original shape may be under stress it was not designed to handle.

Damaged Welds, Joints or Connections

Welds, joints, and connections carry much of a tank’s structural load. Visible deterioration around them calls for closer inspection, since failures at these points can escalate quickly.

Repeated Maintenance or Repair Issues

If the same area keeps needing attention, the visible repair may not be addressing the real cause. A more detailed inspection can help find what is driving the recurring problem.

Unusual Operational Changes

Changes in loading, discharge, vibration, or material flow can reflect a change in the asset’s condition. When a tank starts behaving differently, it is reasonable to look at the tank itself.
One warning sign does not necessarily confirm a serious defect. It does indicate that professional inspection is warranted.

When Should You Schedule a Silo or Tank Inspection?

Beyond visible warning signs, certain events and conditions are good reasons to book an inspection:

• Before putting a new or refurbished tank into service, where applicable
• After major repairs or modifications
• Following an incident, impact or unusual operating event
• When a tank has been in service for a significant period
• When repeated defects or maintenance concerns appear
• As part of a planned inspection and maintenance programme
• When operating conditions or stored materials change

The right timing depends on the tank type, its use, and the applicable standards, so it is best decided together with an inspection specialist.

Why Professional Inspection Is Better Than Relying Only on Visual Checks

Routine walk-arounds are valuable, but they have limits. Operators can spot obvious external issues, yet less visible defects often go unnoticed. Some problems develop in areas that are hard to reach or hidden beneath coatings, insulation, or stored material.

Professional inspectors can choose inspection methods suited to the asset and the suspected issue, such as crack testing where a defect is suspected or thickness measurement where material loss is a concern. Their findings provide maintenance teams with a rationale for what needs to be repaired, what needs to be monitored, and what can be put off for later. This helps to ensure that issues are addressed before they spiral out of control. Industrial inspection services provide this kind of detail for critical assets and also for process equipment such as spray dryer inspection services.

Choosing the Right Tank Inspection Company

Not every provider is equally suited to your asset. When evaluating a tank inspection company, look for:

• Relevant industrial inspection experience in environments similar to yours
• Understanding of silos and storage tanks, including how they are built and how they deteriorate
• Ability to assess different types of defects, from cracks and corrosion to weld issues
• Suitable inspection methods matched to the asset and the concern
• Clear inspection reporting that your team can act on
• Support for further investigation or repair where required

A provider who meets these criteria can do more than find problems. They can help you decide what to do next.

How BioScan Supports Silo and Tank Inspection

BioScan Ltd is an industrial inspection and NDT company that provides solutions for facilities that want to assess the condition of silos and storage tanks. Our Silo Tank Inspection service assists in detecting defects, deterioration, cracks, and other integrity issues that may affect the storage assets.

Our approach looks beyond a single visible problem. Instead of treating one symptom in isolation, inspection helps facilities understand the condition of the asset more systematically, so maintenance decisions rest on the full picture.

This work sits within our broader industrial inspection expertise. Because we understand how silos and tanks operate in a working industrial environment, our findings stay practical and relevant for plant teams. Whether you need Silo and tank inspection services or a wider review of your process assets, our specialists can help you plan maintenance and protect your equipment.

Conclusion

Storage tanks rarely fail without warning. Cracks, corrosion, leakage, deformation, weld damage, repeated repairs and unusual operating behaviour are all signals worth acting on. Pairing those observations with timely professional assessment helps protect safety, product quality and uptime. Tank integrity inspection services offer a structured way to understand what is really happening in and around your assets, and a storage tank inspection can turn uncertainty into clear maintenance decisions.

Not sure about the condition of your tank? Schedule an appointment with BioScan’s inspection specialists today.

A spray dryer does more than remove moisture from a liquid feed. It converts liquids, slurries, or suspensions into a dry powder in a controlled process used across pharmaceutical, food, chemical, and speciality manufacturing. For this process to remain consistent, the drying chamber, atomisation system, air-handling components, and collection system must continue to perform reliably. Continuous exposure to heat, moisture, chemicals, and high-velocity particles can gradually lead to corrosion, cracking, erosion, product buildup, or connection damage.

Understanding spray dryer uses and benefits alongside common spray dryer problems helps operators recognise how equipment condition can affect performance and when professional inspection may be required.

What Is a Spray Dryer, and How Does the Spray Drying Process Work?

Spray dryers dry a liquid or slurry to a dry powder by rapidly evaporating the moisture content. While the concept is simple, the various stages are critically dependent on equipment functioning as intended and operating conditions being carefully controlled.

Feed Preparation

The first step is the preparation of the liquid, slurry or suspension to be dried. The feed should possess appropriate atomisation properties and be suitable for processing. The drying behaviour and the quality of the powders can be affected by changes in the properties of the feed.

Atomisation

The dried feed is added to the drying chamber via an atomiser or appropriate spraying system. It is divided into fine droplets which provide more surface for moisture removal.

Exposure to hot air

The atomised droplets are contacted by heated drying air. Moisture removal is affected by the temperature, airflow and contact conditions.

Moisture Evaporation

The droplets meet with hot air, and moisture evaporates quickly. The remaining solids are in dry particles. The internal surfaces and the chamber need to resist the thermal and process conditions.

Powder Collection

The dried particles are removed from the flow of air and are gathered for additional processing or packaging. The collection equipment and associated components should be in good working order to ensure the efficiency of the process.

Inspection of the dryer chamber, welds, connections, surfaces and other critical areas can help to detect any deterioration that may occur and result in unreliable operation because these stages rely on multiple components.

Spray Dryer Applications and Benefits in the Industry

Spray drying is useful to several industrial sectors because it allows for converting liquid materials into dry materials that are easier to handle. The benefits of spray dryers will depend on product and process needs.

Pharmaceutical Manufacturing

In pharmaceutical manufacturing, spray drying is used to convert liquid formulations, solutions, or suspensions into dry powders with controlled characteristics. By adjusting feed conditions, atomisation, and drying parameters, manufacturers can influence moisture content, particle size, and powder properties required for further processing. The process is particularly useful where consistent powder characteristics are important for formulation, handling, storage, or downstream manufacturing.

Food and Beverage Processing

Spray drying is widely used in food processing to produce powders such as flavours, extracts, nutritional ingredients, powdered milk, and other food products. Consistent drying can help achieve the required moisture level and powder characteristics, supporting product quality, storage, and handling. Since these applications involve continuous operation and strict hygiene requirements, the condition of the spray dryer and associated equipment also needs attention. Regular food industry inspection can help identify corrosion, cracks, surface deterioration, or other equipment issues that may affect safe and reliable processing.

Chemical Manufacturing

Spray drying can be used by chemical manufacturers to convert a liquid chemical formulation or suspension into a dry product that can be more easily stored, transported, handled or used in other processes.

Speciality & Industrial Powders

In speciality and industrial powder manufacturing, spray drying helps convert liquid feeds into powders with characteristics suited to specific processing requirements. Parameters such as atomisation, drying temperature, and feed composition can influence moisture content, particle size, and powder structure. This makes spray drying useful where consistent powder properties are needed for handling, storage, blending, or subsequent manufacturing processes.

Common Spray Dryer Problems that Can Affect Spray Dryer Performance

The equipment is subjected to high stress during spray drying. These conditions may lead to various degrees of deterioration over time.

Corrosion and Surface Deterioration

Equipment surfaces can be impacted by moisture, chemicals, cleaning procedures and exposure to products. Chambers, connections, welds and other exposed surfaces should be checked for corrosion, staining, pitting or other signs of material deterioration.

Cracks and Weld Defects

Cracks or weld defects can be caused by repeated thermal cycling, mechanical stress and vibration, and fabrication problems. Such high-stress areas may thus need more attention. They may need to be monitored, may need repair, or may require further investigation, depending on their size and location. When a defect is suspected, the appropriate industrial crack testing can help to determine the defect.

Erosion and Wall Thinning

Exposed surfaces can be abraded over time by high-velocity particles and continuous flow of product. Depending on the airflow and movement of material, erosion can occur in certain parts of the dryer.

Thickness measurement can be helpful where the loss of material is suspected and is not always evident. The outcome can aid in determining the degree of degradation and if corrective measures are warranted.

Product Build-Up & Deposits

Process conditions, product characteristics or equipment operation can create deposit conditions on internal surfaces that lead to powder accumulation. When there is over-accumulation, heat transfer, process efficiency, cleaning and product handling can be impacted.

Inspection can be used to decide if surface condition or equipment operation needs attention and can be used to find areas where deposits are building up.

Leakage or Damaged Connections

Over extended periods of use, flanges, joints, seals, access points and other connections can deteriorate. If leakage is seen, the seals may be damaged, connections may be loose, corrosion, cracking or mechanical problems may be present that need to be investigated.

Deformation or Structural Damage

Equipment geometry can be influenced by thermal stresses, mechanical loads, pressures and other operating conditions. Dents, distortions, buckling, or other abnormal changes should be investigated immediately to determine the cause and impact of such changes on equipment integrity.

Spray Dryer Inspection Services offered by Bioscan Ltd.

Bioscan Ltd. is an industrial inspection and NDT company for spray dryers and related process equipment. Our spray dryer inspection is highly regarded for gaining a picture of the equipment condition and areas that need further inspection.

The assessment will cover:

• Assessment of conditions and integrity of equipment.
• The identification of cracks and surface defects.
• Assessment of deterioration and corrosion.
• Evaluation of welds, joints and areas of critical importance.

With BioScan LTD, the facility can early identify the deterioration. It tremendously helps assist the operator in planning maintenance and repair, investigating recurring problems, and planning equipment condition.

How to Maintain Spray Dryer Reliability After Inspection

Inspection provides useful information, but its value depends on what happens afterwards. Once defects or vulnerable areas have been identified, maintenance decisions should be based on the inspection findings and the equipment’s operating requirements.

• Identified defects should be addressed according to their severity and the recommendations of the inspection. If repair or component replacement is required, it should be completed within the appropriate maintenance plan.
• Previously vulnerable areas should also be monitored during subsequent inspections. Cleaning and operating procedures should be maintained appropriately to minimise conditions that contribute to deposits, corrosion, or accelerated deterioration.
• Periodic inspections should be scheduled according to equipment condition, operating environment, and maintenance requirements. Keeping inspection and repair records can also help identify recurring problems and track how equipment condition changes over time.

Conclusion

Understanding spray dryer uses and benefits is only one part of maintaining reliable drying operations. The same equipment that provides controlled moisture removal and powder production can experience common spray dryer problems, including corrosion, cracking, erosion, product buildup, connection damage, and deformation during continuous operation. These conditions can develop gradually and may not always be obvious from routine observation.

A structured spray drying process assessment should therefore consider both process performance and equipment condition. Regular inspection can identify deterioration, assess critical areas, and provide information for maintenance decisions. With appropriate inspection, repair, monitoring, and operating practices, manufacturers can better protect spray dryer integrity and support consistent long-term operation.

Need to assess your spray dryer? Speak with Bioscan’s inspection specialists about the condition of your equipment. Talk to Our Inspection Specialists now!

Stainless steel is widely used in industrial equipment due to its strength, durability and good resistance to corrosion. However, exposure to heat, moisture, chemicals, vibration, pressure and abrasive materials affects the metal. Thus, welds can crack, exposed surfaces can corrode, and materials can become thinner over time.

Knowing about some of the most frequent problems in stainless steel equipment lets the team identify warning signs through inspection and take appropriate maintenance or repair action.

Common Stainless Steel Equipment Defects Found During Industrial Inspections

Common issues that inspectors are likely to identify are:

Cracks and Hairline Cracks

Any crack in the wall, no matter how small, or even just a hairline, should be looked at. The defect may grow if the system is left in operation, leading to leakage or loss of structural strength. A suitable inspection technique will be needed to identify the extent and location of defects.

Pitting and Localised Corrosion

Moisture, chemicals, chlorides, process residues, and deposits promote pitting. It may be counted as a small surface imperfection but affect the material beneath the surface. Also, stainless steels are corrosion resistant but may get localised corrosion under certain conditions. Equipment inspection should therefore focus more on areas exposed to moisture, chemicals or process material.

Weld Defects

Welds are significant inspection locations, as they can be prone to defects during manufacture or during service. They include weld cracks, incomplete fusion, porosity or other abnormal weld conditions. A simple visual inspection may not be sufficient in determining the condition of a suspicious weld. Targeted NDT may then be beneficial if a weld requires more detailed investigation, especially if the location is under mechanical stress, vibration, pressure, or temperature extremes.

Wall Thinning and Material Loss

With time, equipment thickness may decrease due to corrosion, erosion and operation. Material loss can occur without being noticed from the outside. Measurement of thickness can be helpful in mapping the zones where thickness is reduced.

Deformation and Distortion

At high velocity, abrasive materials and particles can gradually wear stainless steel surfaces. Inspection helps to determine whether the damage is superficial or it has reached material loss and needs a corrective measure.

Surface Damage and Erosion

Excessive pressure, temperature fluctuations, mechanical loads, vibration, or operating conditions can cause equipment geometry changes. These can be seen as dents, buckling, warping, bulging, and more. Inspection offers the opportunity to understand how much it has occurred and what has caused it before it worsens.

Corrosion Around Connections, Seals and Difficult Areas

Repeated loading, vibration, thermal cycling, or even localised loading can cause cracking around welds, joints, bends, connections, and other high-stress areas on equipment. Continuously operating tanks, silos and process equipment could be especially vulnerable since they are subject to continuously changing process conditions. During inspection, pay attention to these areas to help detect early signs of corrosion, cracking, leakage or damage.

Where These Defects Can Occur in Industrial Processing Equipment

Spray Dryers

Heat, product flow, humidity, and erosion are the dangers that spray dryers face. Cracks, corrosion, thinning, and surface deterioration can then occur at various points, such as chambers, welds, internal surfaces, and connections. Spray dryer inspection services can help identify these issues based on their operating condition.

Silo and Tank Systems

Silo and tank systems must be maintained around the walls, roof, welds, supports, connections and joints. These areas can corrode, crack, deform or experience loss of material depending on the material stored and the environment. Silo and tank inspection services facilitate the deterioration identification before it undermines the equipment integrity.

Cyclones

Cyclones can develop equipment deterioration in areas exposed to continuous process flow and operating stresses. The internal surfaces, inlet and outlet sections, bends, joints, and welded areas can be examined for signs of surface damage, erosion, cracking, corrosion, or material thinning. Cyclone and bag filter inspection helps determine whether the observed deterioration is limited to the surface or has progressed to a condition that requires repair or further evaluation.

Bag Filters

Both the equipment body and welds are liable to deteriorate during operation. Cyclone and bag filter inspections may reveal damage to the surface, deformation, corrosion, or other issues which may necessitate maintenance.

How Stainless Steel Equipment Inspection Detects Defects

Based on the type of defect and equipment being inspected, the approach to the inspection can be determined after identification of vulnerable areas. If necessary, Bioscan’s method can be used in conjunction with appropriate testing techniques.

Visual Inspection

The first inspection of visible cracks, corrosion, deformation, surface damage, leakage and other abnormalities is conducted using a visual examination. It may also be able to pinpoint areas that need further investigation.

Non-Destructive Testing

Not every defect can be fully judged by visual inspection. Tests, like NDT, can provide more data without harming the machine. Based on the inspection goal and applicability, techniques like ultrasonic testing or dye penetrant testing may be used for inspections.

Thickness Assessment

Thickness measurement is especially helpful to detect wall thinning and material loss due to corrosion or erosion. A comparison of measurements from relevant areas can be helpful in determining areas of deterioration.

Weld and Joint Examination

Specific areas of welds, joints, supports, and connections can be analysed in detail, as they can endure higher stresses and can be a site for defects. An inspection technique may be chosen based on the condition.

Condition Assessment and Reporting

Equipment conditions should be documented during inspections to provide an understanding. The findings can be used to determine areas for repair, ongoing monitoring, or additional technical review.

Industrial Equipment Inspection by Bioscan Ltd.

Bioscan Ltd is a specialist provider of industrial equipment inspection services for processing and storage equipment. Bioscan’s inspection work focuses on cracks, corrosion, wall thinning, weld-related defects, surface deterioration, and structural or mechanical damage. The inspection approach can combine systematic visual assessment with suitable NDT and thickness assessment techniques based on the equipment and inspection requirements.

This provides plant teams with documented information about equipment condition rather than relying solely on routine visual checks. The findings can support maintenance, repair, monitoring, and further investigation decisions. Where a specific tank-related problem requires closer assessment, Bioscan also offers industrial tank defect investigation.

Conclusion

Stainless steel can withstand demanding industrial environments, but continuous operation can still lead to cracking, pitting, weld defects, wall thinning, deformation, erosion, and corrosion around connections. These stainless steel equipment defects may develop gradually and are not always obvious during routine operation. Their location and severity also depend on the equipment and operating conditions.

A structured stainless steel equipment inspection connects these warning signs with the actual condition of the equipment. Visual examination, suitable NDT methods, thickness assessment, and condition reporting can provide a more complete understanding of deterioration. Regular industrial equipment inspection can therefore help plant teams identify problems earlier and make informed decisions about maintenance, repair, and further assessment.