Burkert Saves £120,000 per annum - or 40% - in CIP costs for major pharmaceutical manufacturer
Converting a manual CIP process to automatic across 80 reaction vessels, using pressure transmitters, condition sensors and flow meters, has enabled Burkert to achieve savings of £120,000 per annum for a major UK pharmaceutical manufacturer.
Prior to the installation of the Burkert system, the reaction tanks were each cleaned for 6-hrs, constantly flushed to drain with hot water at 700C. This was a purely manual process based upon operator experience, rather than positive signals from the process that the cleaning procedure was complete.
The weekly costs for the manual cleaning procedure were substantial: energy costs were running at around £4000, with water at approximately £1,000 and effluent costs approaching the same figure. In total, the combined weekly figure across all activities included in the cleaning was £5,900; or a considerable £295,000 per annum.
Keen to reduce these costs, engineers at the pharmaceutical manufacturer contacted Burkert. This resulted in a site visit to view the manual CIP process. Following the visit Burkert suggested a solution for each reaction vessel based upon a Type 8311 pressure transmitter, a Type 8222 condition sensor and a Type 8041 flow sensor.
These products were installed on a test group of the vessels and linked the plant SCADA system. The CIP process was then undertaken in an automatic mode, with the 8222 condition monitor providing effective feedback of when the water in the vessel was clean - and hence the vessel itself - to the SCADA system, which terminated the process.
On the basis of the initial tests, engineers at the pharmaceutical plant calculated that their CIP costs would be reduced by 40%, or £120,000 per year using the Burkert equipment.
"This application highlights the savings that can be achieved on even the simplest of processes, as a result of consulting our specialist engineers," said Burkert UK Sales Manager, Neil Saunders. "All business sectors today are incredibly competitive, so all opportunities to exploit so-called 'low hanging fruit' have to taken and optimised upon. With our specialist knowledge and leading edge product range this is exactly what we do: and the results speak for themselves, as evidenced by this application."
Bürkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 1,800 people and has a comprehensive network of branches in 33 countries world-wide.
For further information please email Burkert Fluid Control Systems