The National Foods manufacturing site in Lytton has had a long history with Spirax Sarco and has always seen the benefit in being proactive in maintaining and improving its steam system. So when in late 2009 National Foods noticed the boiler’s softened makeup water rate increasing, they called Spirax Sarco to investigate. After conducting a regular steam trap audit, Spirax Sarco’s service department repaired failed units and installed a conductivity-based TDS system on the boiler (3MW WT).
The Lytton site is one of the juice manufacturing sites that National Foods operates in Australia. To ensure it remains viable in the future it is imperative that the entire site operates as efficiently as possible. To try to uncover the source of the increased water issue Spirax Sarco initially performed a routine steam trap audit, which identified some failed main line steam traps and some issues surrounding two process pumping traps. Further losses were uncovered in the boiler house relating to the operation of the boiler blowdown system.
David Curry, water treatment service supervisor, was able to show history over a long term, depicting the chemical and TDS concentration levels which uncovered a fault in the boiler’s TDS controller unit.
With the support of the engineering sales and service teams the TDS control system was repaired, instantly showing improved chemical control and a tighter TDS control band produced. After the TDS issue was resolved, the Spirax Sarco service team was called in. Steve Ennion, service supervisor, oversaw the repairs to the failed steam traps and pumping traps. Once these repairs were finished, along with the fully operational TDS system, a 75% make-up water rate reduction was experienced.
With the combination of the three Spirax Sarco business units a water saving of up to 11,000l per day was achieved at this site.
Optimum process efficiency and production quality
On-going service and maintenance is imperative to ensure optimum process efficiency. In addition to the savings in water at the National Foods Lytton manufacturing site, there has been an improvement in the consistency of the production temperature, ensuring continued production quality.
Is your plant running as efficiently as possible? The entire Spirax Sarco team can be utilised on your site to help overcome efficiency losses.
Spirax Sarco has a unique ability to provide solutions in all areas of your steam plant. By combining our engineering and water treatment teams we are able to understand your business in all sectors and highlight savings in both the boiler house and process areas.