Opportunity
The Sayaji (an association with Alland, a France based company) presented a critical requirement to use a novel, chemical-free procedure for Non-Destructive Testing (NDT) for crack inspections. They had specific concerns about traditional chemical penetrants and dyes, as residual dye post-Clean-In-Place (CIP) could potentially impact product quality. Although the water-soluble dyes typically used are easily removed, this extra precaution was essential for Alland's strict hygiene standards. To meet this requirement, PMG utilized an innovative NDT method utilizing a chemical-free approach through ultrasonic Magnerscan technology for crack and crevice detection.
Solution
PMG via Magnerscan, - use hand held device that requires the user to simply swipe across a metallic surface. Cracks are detected via audible sound and a graph on the monitor that indicates a crack. This method offered a 100% surface inspection, ensuring comprehensive testing without compromising risk. The testing spanned approximately four days to cover all zones of the 8 TPD vegetable powder spray dryer, with sections strategically divided for thorough inspection. The Magnerscan equipment, procured specifically from the UK for this project, provided detailed imaging for each section, capturing any potential points of concern.
In addition to crack detection, Ultrasonic Thickness Measurement (UTM) was performed to assess any material degradation within the dryer. On-site rectification was executed for identified issues, followed by a complete re-inspection to confirm all repairs met Alland’s stringent safety and hygiene criteria.
Outcome
PMG’s timely and effective approach led to the successful execution of the NDT crack test, ensuring zero chemical use and meeting Alland’s high standards for food safety and hygiene. The final report, delivered promptly to the client, confirmed the dryer’s integrity and quality, satisfying Alland’s operational requirements. Based on the results, PMG recommended annual testing as part of a preventative maintenance plan to monitor dryer degradation and maintain optimal quality.
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