Case Study

Context

A major dairy products manufacturer in the Netherlands encountered a grave concern when abnormal microbes were detected in a sample from their largest spray dryers. Fearing the possibility of contamination spreading through their products, the company quickly mobilised to address the issue. With the risk of an operational halt on the horizon, the company faced a critical moment that required decisive action to mitigate the potential impact on their business operations.

Challenges

We were called in on a tight deadline to identify the root cause of abnormalities found in the samples. Our task was to perform a full internal scan of the spray dryer and carry out all necessary repairs within 24 hours of the call.

The Bioscan Response

Bioscan’s emergency rapid crack detection team was deployed on the site. We performed a full internal scan of the spray dryer to detect and repair any cracks, minimise downtime, and ensure food safety compliance.

Outcome

We detected multiple micro-cracks through our micro-crack detection methods near the weld seams, which were not visible to the naked eye. Bioscan, a leading provider of inspection services, carried out localised repairs during the shutdown window and resumed production within 24 hours. With our highly effective crack detection services, we helped the dairy plant avoid significant costs, estimated at over 1 million Euros in downtime and lost output. We were praised for completing the dairy plant inspection through crack inspection services within 18 hours of arrival. 

Impact

This case underscores the power of real-time, accurate defect detection through nondestructive testing. Without Bioscan’s rapid spray dryer inspection, they could have faced the risk of contamination and massive financial and operational losses. Instead, they transformed an emergency into a successful mitigation story.

If you are looking for an effective and rapid-response-equipped industrial inspection company, look no further than Bioscan. Our industrial inspection services are designed to carry out any emergency industrial inspections within tight deadlines. Contact us today; we are just a call away!

Context

A leading US-based infant formula manufacturer reached out to Bioscan to conduct a comprehensive spray drying inspection. Their goals were to ensure that every component of the spray dryer (which transforms liquid concentrate into powder formula) system meets the strictest hygiene and safety standards. 

Challenges

The request was to detect early signs of cracking, maintain full compliance, and perform repairs with a tight 48-hour shutdown window. In short, we had to perform a full inspection and repair of the spray dryer system during the scheduled shutdown through our non-destructive inspection technology. 

How We Approached the Challenges

Bioscan mobilised a team to the site, using our proprietary non-destructive electronic inspection methods to initiate testing. With IRATA-certified rope access, we inspected the entire spray dryer chamber and cone, fluid bed, ducting system, and cyclones, without the need for scaffolding, then performed the welding repairs.

Outcome 

Upon thorough food industry equipment inspection, we identified some potentially vulnerable non-visible cracks and biofilm-prone areas and addressed them on the spot. With the help of our highly skilled technicians, we completed the entire inspection and repaired cracks within the deadline. We also delivered a comprehensive report, covering every issue we had identified during the inspection and repair for future maintenance planning.

Impact

The client gained accurate insight into asset health, minimised risks of contamination, and avoided emergency downtime. The inspection supported global compliance and helped the team build a predictive maintenance strategy, demonstrating the efficacy of our vessel crack test inspection services. 

This case study is a testament to our expertise in real-time nutritional food processing equipment inspection. We rigorously strive to ensure every inspection is carried out with the highest level of accuracy, leaving no defect undetected. Our precision in spray dryer crack inspection helps clients avoid unexpected shutdowns, supports audit readiness, and keeps costs and disruptions to a minimum.

If you are ready to have your spray dryer system inspected through our high-quality and effective spray dryer inspection services, contact us today. We are just a call away!

Context

A multinational food processing manufacturer based in Europe, required full audits for over 40 tanks and silos. They knew that traditional methods of inspection would have been too time consuming for them. Therefore, they contacted BioScan, a provider of effective and high-quality tank integrity inspection services to perform the project within a tight deadline. 

Challenges

Our task was to detect cracks at weld seams and stress points, and to assess corrosion and mechanical wear, among other issues. In short, we had to inspect the overall health of more than 40 tanks and silos within the assigned deadline.

How We Dealt with the Challenges

We deployed IRATA-certified rope access technicians into tanks and silos. They were equipped with electronic crack detection equipment. They checked each weld seam and stress point for cracks, assessed traces of corrosion, and mechanical wear. During the inspection, we flagged 17 cracks for repair and discovered multiple corroded and damaged points.

Outcome

We repaired 44 tanks and silos over a span of four weeks, ensuring that every crack and defect was addressed. After inspecting every vulnerable point, our well-trained and skilled technicians performed on-the-spot silo tanks repairs, making all tanks and silos audit-ready while keeping silo maintenance costs low.

This case study is a testament to our expertise in real-time silo inspection and repair. We rigorously strive to ensure every inspection is carried out with the highest level of accuracy, leaving no defect undetected. Our precision in silo crack testing helps clients avoid unexpected shutdowns, supports audit readiness, and keeps costs and disruptions to a minimum.

If you are ready to have your silos and tanks inspected through our high-quality and effective tank inspection and engineering services, contact us today. We are just a call away!