Alfa Laval Tank Cleaning Getting the most out of tank cleaning with Gamajet and Toftejorg devices
Agenda Introduction Who we are What we sell Where and to whom we sell it Cleaning Overview Motivations The factors of cleaning Common Methods of cleaning
Who we are Alfa Laval is a global supplier of heat transfer, separation and fluid handling systems We are the North American tank cleaning competency center for Alfa Laval Gamajet and Toftejorg tank cleaning devices are the product ranges available through Alfa Laval Static spray balls Rotary sprayheads Rotary jetheads Alfa Laval
Cleaning solutions for customers Technology used in the cleaning of process and transportation equipment. Think about confined spaces that your customers clean. Equipment as varied as fermenters, reactors, dryers, rail cars, blending tanks, to name a few. Ask: do you clean this? Alfa Laval Slide 9
Reasons for Cleaning Need to return a tank or piece of process equipment back to its original condition to ensure batch integrity. Physical appearance Performance Flavor and aroma Avoid reactions Protection against contamination. Bacterial infections In order to and safely consistently make the same product, our customers must begin with a clean tank! Alfa Laval Slide 10
Why is tank cleaning important to our customers? Product quality: Are you experiencing any cleaning issues? Health & safety: Are you using manual labor to clean? Costs & efficiency: Are you challenged to clean in less time, while using fewer natural resources? Production & uptime: Are you sold out? Are you planning an expansion?
Interest at multiple levels Stakeholders are throughout the customer s organization. Engineers Production Sustainability managers EHS manager Quality Manager/Sanitarians Plant Managers Alfa Laval Slide 12
Why should you care? Industry leading product lineup Dedicated, reliable, and expert support Current cleaning processes are outdated, wasteful, and potentially dangerous. An engineered solution for your customer High margin item that will many times be the smallest piece of the project. Sets you apart from the competition Gain access to new customers Deepen your relationship with existing customers Alfa Laval Slide 13
How are we going to do it? Recruit, develop, and support distributors. Dedicated Regional Sales Managers 75% travel in the territory Target accounts, large projects, field calls Generating new opportunities Inside Sales Support Single point of contact Technical support and customer service Lead generation through marketing 5 trade exhibitions per year ~25 web leads per week Advertisements and regular e-communications Alfa Laval Slide 14
The basics of tank cleaning Alfa Laval Slide 15
Factors of cleaning Primary factors Time Temperature Chemical action Mechanical force Secondary factors Soil/residue -Type, condition, amount Surface material Accessibility Alfa Laval Sinner s Circle: The relationship between time, temperature, chemical action and mechanical force to obtain an effective clean Dr. Herbert Sinner (1959)
Obtaining an effective clean Temperature hot water CLEANING THE DISHES: AN EVERYDAY EXAMPLE OF THE SINNER S CIRCLE Chemical action soap Time soaking overnight Mechanical action scrubbing Alfa Laval Slide 17
Obtaining an effective clean Temperature hot water CLEANING THE SINK: AN EVERYDAY EXAMPLE OF THE SINNER S CIRCLE Chemical action soap Time soaking overnight Mechanical action scrubbing Alfa Laval Slide 18
Methods of tank cleaning There are multiple ways to clean a tank. Knowing these will help you determine the best solution for your application. Methods: Manual cleaning Boiling out/ fill and drain Static spray ball Rotary sprayhead Rotary jethead Alfa Laval Slide 19
Efficiency Matrix Reliable, but slow Reliable, fast cleaning Rotary jethead Static spray ball Rotary sprayhead Manual cleaning Boiling out/ fill and drain Not reliable, slow Alfa Laval Slide 20
Manual cleaning The process of entering the tank and manually cleaning with a hose, pressure washer, or scrubbing mechanism Problems with manual cleaning: Human error Labor expense Time Confined space entry dangers -Falling -Inhalation of fumes Alfa Laval Slide 21
Boiling out/fill and drain The process of filling a tank or vessel with a concentrated chemical solution and then heating the tank to remove the toxins and residues. Problems with boiling out: Time-consuming Requires too much water Unreliable Alfa Laval Slide 22
Static spray ball Designed to cascade cleaning solution and erode away residue on the walls of the tank with chemical cleaning agents. Pros: Inexpensive Effective for easy to clean residues Easy change-out Alfa Laval Slide 23
Static spray ball Cons: Very little mechanical force Will struggle to clean tough residues Wasteful of resources Low flow areas Clogging of holes will result in loss of 100% coverage Alfa Laval Slide 24
Rotary sprayhead A rotary wetting device provides various coverage options to create a sheeting action on tank walls. Pros: A step up in cleaning effectiveness, at an economical price Higher Impingement Dynamic pattern Plug and play Hygenic and self cleaning Cons: Time-consuming if used in the wrong application Alfa Laval Slide 25
Rotary jethead A fluid-driven device that optimizes the pressure and flow to create high impact cleaning jets that produce mechanical force that scour the tank interior in a complete 360-degree pattern. Pros: Excellent for cleaning stubborn residues Least amount of water and cleaning chemicals Least amount of time to clean Repeatable Typically large ROI Cons: Overkill for easy to clean residues Most expensive up front More complicated change-out Alfa Laval Slide 26
IMPACT: Mass at a Velocity Force and Tangential Force Theoretical Impact = 0.0526 x (GPM) x (PSI) Notice that the equation uses the square root of the pressure. For this reason doubling the pressure will not double the impact at the same flow rate. If you double the flow rate and maintain the same pressure, the impact will double. Alfa Laval Slide 27
Contributing Factors Operating conditions Distance Angle Rotational speed Obstructions Alfa Laval Slide 28
Cleaning around Obstructions Impingement will create ricochet or bounce effect Can assist in shadow coverage created by internal geometries Consider the impact and the contributing factors Pattern Cycle
Mechanical force in a precise, controlled and validatable pattern Indexing impact through gear ratios Full 360-degree coverage over time 360 degree cyce Mechanical cycle Cleaning cycle Repeatable and reliable Alfa Laval Slide 30
Pattern Development Precise pattern development ensures the most efficienct cleaning process. Our competitors must run longer cycles to ensure the same coverage, resulting in higher consumption of energy, water, chemicals = higher cleaning cost Competitors pattern 2 Minutes Alfa Laval Pattern 2 Minutes Benefit : Alfa Laval cleaning pattern allows for the customer to clean faster using less water and chemicals = lower cleaning cost Alfa Laval Slide 31
How does mechanical force delivered in a precise, repeatable pattern affect cost to clean? Up Front Costs: One-time investments Mechanical force Rotary Jet Head Operating Costs: Continual expenditures Time: The most expensive Labor Lost production Energy Chemicals Water We will prove a ROI! Alfa Laval Slide 32
Service & repair program 24-48 hour turnaround on parts, repairs, new orders, quotations Comprehensive repair program includes: A tear down of the machine Ultrasonic cleaning Detailed inspection Reassembly Hydraulic testing at customers operating conditions Renewed warranty with all repairs and new machines Alfa Laval Slide 33
Customers served 19 out of the Top 25 Food and Beverage companies 14 out of the Top 15 Pulp and Paper companies 9 out of the Top 10 Personal Care companies 9 out of the Top 10 Pharmaceutical companies 9 out of the Top 10 Wine companies 4 out of the Top 5 Ethanol/Grain companies 4 out of the Top 5 Transportation companies Alfa Laval Slide 34
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