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Project

NDT Crack Test for 30 TPD Spray Dryer and Cyclone For Food Safety Complainace

Opportunity

Lactalis (Sunfresh Agro) established a proactive yearly procedure for compliance checks focused on food safety through high-precision crack testing as part of its preventive maintenance program. Given that the Spray Dryer and Cyclone operate under continuous stress, heat, and cleaning cycles, this routine inspection aims to detect surface discontinuities like cracks or thinning that could compromise equipment integrity or product safety. Conducting advanced non-destructive testing (NDT) within a live production environment, while maintaining strict hygiene compliance, ensures ongoing protection of food quality and supports adherence to internal quality standards.

Solution

To ensure thorough and reliable inspection aligned with the proactive food safety compliance checks, PMG Engineering deployed a dedicated team consisting of two ASNT Level II certified technicians and a mechanical process engineer. The team conducted a comprehensive assessment of the Spray Dryer and Cyclone, performing visual inspections to identify any visible surface irregularities, ultrasonic thickness measurements (UTM) to detect areas of material thinning, and dye penetrant testing (DPT) to reveal surface cracks or discontinuities not visible to the naked eye. All testing followed the rigorous standards set by ASME Section V and adhered strictly to the factory’s safety and hygiene protocols, ensuring minimal disruption within the live production environment. The inspection uncovered minor pitting and pinholes primarily localized around critical areas such as cone welds and dish nozzles, while no major cracks or structural failures were detected. Following the testing, PMG Engineering compiled a detailed and comprehensive report that included precise thickness readings, a log of all detected defects, high-resolution test photographs, and calibration certificates for all testing instruments. This report was then jointly reviewed onsite with the client’s team, fostering transparent communication and enabling proactive decision-making for maintenance and operational continuity.

Outcome

The Non-Destructive Testing (NDT) of the Spray Dryer Chamber and Cyclone confirmed the integrity and reliability of the equipment, with no visible defects or deformations detected. All ultrasonic thickness measurements comfortably exceeded the minimum acceptable threshold of 2.0 mm, indicating sufficient material thickness throughout. Critical surface anomalies such as cracks, crevices, pinholes, or dents were absent, and the minor indications identified during Dye Penetrant Testing were assessed as non-critical and rated “satisfactory.” Based on these findings, PMG Engineering recommended maintaining an annual crack testing schedule to ensure ongoing monitoring and early detection of potential issues. Additionally, it was advised that the comprehensive inspection report be shared with the original equipment manufacturer (OEM) for further lifecycle evaluation. The project was completed successfully, with full documentation delivered and strict adherence to food-grade safety and hygiene standards maintained throughout.

Project Highlights

Established an annual NDT program for food safety compliance

Used Visual Inspection UTM and DPT by certified technicians

Followed ASME standards and strict hygiene protocols

Found no critical defects; thickness above minimum limits

Delivered detailed reports reviewed jointly with the client

Key Challenges

Conducting precise NDT during active production

Maintaining strict food-grade hygiene throughout testing

Detecting minor surface defects accurately

Coordinating between technical and client teams

Completing testing within tight maintenance schedules

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Location

Ahmadnagar, Maharashtra, India

Client

Sunfresh Agro Ltd

Project Status

In-Progress

Services Provided