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Why Regular Spray Dryer Crack Inspection Matters?
Ensuring operational efficiency and product safety are paramount in any industrial setting. With that in mind, it’s crucial to acknowledge that all spray dryers, at some stage during their lifetime, will begin to develop cracking and defects within the stainless-steel weld joints or the sheet metal itself. This is due to the dryer being exposed to varying mechanical and chemical impacts during operation.
It is important to perform regular spray dryer crack test inspections to catch issues early:
- By repeatedly reducing or maintaining the number of cracks present, it lowers the potential for bacterial growth and possible cross-contamination. Therefore, increasing the safety of the product and the safety of the end consumer.
- Performing consistent annual/biennial crack testing inspections can enable extended life cycles of the asset, as cracks and defects are identified in their early stages before they potentially lead to bigger concerns.
- Preventing extended downtime for when larger corrective actions may be required; such as cutting out and replacement of certain areas, or complete replacement.
- The reporting and certification documentation received after the inspection adheres to internal and external audit requirements, giving your clients more confidence in your processes and procedures.
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Spray Dryer Crack Detection and Inspection Procedure
A complete spray dryer crack testing, including repairs, can be carried out within 24/48 hours, ensuring that your downtime is minimised and you are quickly back into production.*
- At Bioscan, we determine the best access method to use. Our bespoke gantry platform, rope access, ladders, or a combination. This ensures that no scaffolding is required, and Bioscan’s technicians can perform efficient spray dryer crack inspection and maintenance.
- 100% inspection surface coverage using Bioscan’s electromagnetic crack scanning technology. With this technology it enables us to detect non-visible cracks/defects, and there are no dyes/chemicals required. Therefore, it is a cleaner and more accurate inspection method compared to our competitors’.
- Our fully qualified and competent welders perform the required repair and polishing works to meet food grade standards (client may also use their on-site or local welders)
- Repeat the inspection of any repaired areas. This is critical to ensure that after the welding and polishing process, no further cracks/defects have appeared in the HAZ (heat-affected zone)
- Removal of all tools/equipment from the spray dryer and handed back to the client for CIP and production.
*(extra time may be required depending on repair works to be performed)
Fluid Bed System Inspection & Repair
In addition to the spray dryer inspection services, Bioscan can also inspect and repair the upper and lower compartments of the fluid beds, which are critical components in relation to the complete drying system.
FAQ’s
Why is regular spray dryer inspection important?
Regular inspection of spray dryers is important for several reasons. It includes spray dryers that go through thermal cycles, mechanical stress, CIP, and corrosion. Over time, these stresses lead to cracks, corrosion, weld defects, and other integrity issues. Undetected defects may lead to unplanned downtime, costly repairs, safety risks, or product quality and recalls. Hence, regular inspection of spray dryers is vitally important to negate the mentioned issues.
How often should spray dryer inspections be performed?
Bioscan recommends that the frequency of inspections be regular, at least once a year. We have various case studies to support this, including one where a client waited five years between inspections. As a result, the inspection uncovered many defects. If the inspections had been done on time, they would not have had to face cost and risk issues. Hence, ensure the inspections are done regularly to negate the cost and risk issues.
What inspection technology does Bioscan use?
Bioscan uses state-of-the-art electronic/non-destructive testing technology and refrains from dyes and chemicals. Our modern detection tools are capable of detecting visible and non-visible defects, like cracks, incomplete welds, corrosion cavities, porosity, etc.
How long does a full spray dryer inspection take?
With its modern inspection tools and highly qualified technicians, Bioscan is capable of completing the full spray dryer inspection and repairs within 12-48 hours. In addition to inspection, the duration may extend if extensive repairs are required.
Does Bioscan offer repairs during the inspection?
Yes, Bioscan always offers welding repairs and food grade polising during the project.