ACOUSTIC IMAGING KEY IN LEAK BEST PRACTICES TO MAKE PLANT TURNAROUNDS www.processingmagazine.

com
DETECTION AND DOWNTIME REDUCTION p30 MORE EFFECTIVE AND EFFICIENT p32 APRIL 2024

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POWDER & BULK

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 CONTENTS
APRIL 2024 | VOL. 37 | NO. 4

COLUMN: Asset Management

8 Driving efficiency: Strategies for

launching and scaling APM solutions
Supported by the right strategy and roll-out, asset performance
management solutions can improve equipment and process
efficiency within a short timeframe.

COVER SERIES: Powder & Bulk Processing

12 Rotary dryer or fluid bed? Let the operation decide

12
The best dryer type for a given project often depends on how
each dryer’s operation will impact the material and facility.

16 Bulk bag filler upgrades target the bottom line

Best practice strategies to help food and beverage processors increase
productivity and profit by upgrading critical bulk bag filling equipment.

22 Q&A: Titanium dioxide safety and

regulation in foods and pharmaceuticals
Ongoing efforts to ban the ubiquitous pigment TiO2 do not align with
recent statements from international regulatory agencies.

FEATURES

27 Data estate modernization holds the key to

smarter and more sustainable chemical processing
Chemical processors must first modernize their data estates before
they can truly make headway with their smart manufacturing plans.

16 30 Acoustic imaging key in leak

detection and downtime reduction
Acoustic imaging can go a long way in quickly and
cost efficiently identifying and repairing leaks, saving
companies in downtime while making needed repairs.

32 Best practices to make plant turnarounds

more effective and efficient
Proper planning with trusted partners can
make turnaround efforts go more smoothly.

36 Digital tools reduce project execution time

New software tools create instrumentation lists automatically from
P&IDs, eliminating errors and increasing personnel productivity.

27 32

www.ProcessingMagazine.com Facebook Twitter LinkedIn

facebook.com/ProcessingMagazine @ProcessingMag linkedin.com/showcase/27062974

2 Processing | APRIL 2024

 20
DEPARTMENTS

4 Editor’s Note
6 Industry News
10 Product Focus: New Products
20 Product Focus: Powder & Bulk Processing
39 Advertiser Index
40 ProcessingMagazine.com

11 ACOUSTIC IMAGING KEY IN LEAK

DETECTION AND DOWNTIME REDUCTION p30
BEST PRACTICES TO MAKE PLANT TURNAROUNDS
MORE EFFECTIVE AND EFFICIENT p32
www.processingmagazine.com
APRIL 2024

SUBSCRIBE TO OUR

POWDER & BULK

Cone crusher
Metso
DIGITAL
EDITION
www.metso.com
p20

DRYING p12

CHEMICAL
METERING PUMP
Watson-Marlow
Fluid Technology
www.wmfts.com
p10

2404PRO_C1-C4_Cover.indd 1 4/3/24 10:18 AM

Cover image: Courtesy of FEECO International

Highest Level of Protection

Against Dangerous Tramp Metals
Eriez offers a wide range of
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get metal out.

Eriez.com | 814.835.6000

2312PRO_EriezMagnetics.indd 1 APRIL 2024 | www.processingmagazine.com

11/27/23 1:45 PM 3
 Publisher Keith Larson
klarson@endeavorb2b.com.com

CONTENT

EDITOR'S NOTE Chief Editor Jesse Osborne

josborne@endeavorb2b.com

Managing Editor Daniel Gaddy

dgaddy@endeavorb2b.com

Senior Editor Nate Todd

ntodd@endeavorb2b.com

W
Art Director Ryan Carlson
elcome to the April issue of Processing. rcarlson@endeavorbusinessmedia.com
This issue features our latest cover series Production Manager Josh Troutman
on powder and bulk processing and jtroutman@endeavorb2b.com
includes three articles on that important
topic for processors. ADVERTISING
Leading things off is an article by District Manager Jay Haas
Nick Reckinger of FEECO International that exam- 281-980-5831 | jhaas@endeavorbusinessmedia.com
ines powder and bulk solids drying. Reckinger writes: Account Manager Lisa Williman
“Often working to meet stringent quality standards 518-322-6691 | lwilliman@endeavorbusinessmedia.com

and tight deadlines against small profit margins, pro-

ducers require their drying systems to be efficient, I hope you find the content in this issue both interest- MARKETING
reliable and able to consistently produce material ing and informative. As always, thank you for reading. Digital Product Director Nick Phillips
according to specification. nphillips@endeavorb2b.com
“Both rotary dryers and fluid bed dryers can meet
these objectives, which can make the choice between Ear on Processing podcast — now weekly Digital Operations Manager Mary Beth Romano
mbromano@endeavorbusinessmedia.com
the two types unclear in some settings, particularly Our podcast — Ear on Processing — is now releasing
episodes on a weekly basis. Marketing Manager Lexi Richards
given the amount of overlap in applications historically alexisr@endeavorbusinessmedia.com
seen. However, with each dryer type offering distinct dif- Ear on Processing takes listeners inside the pages of
Audience Development Manager Anna Hicks
ferences, the choice between them often becomes clear Processing magazine and into the minds of subject matter ahicks@endeavorbusinessmedia.com

when considering how each dryer operates. The result-
ing implications on the material and facility will often
influence the decision of which dryer type to select.”
Next, Del Williams outlines best practices for food and
beverage processors as it relates to upgrading bulk bag
filling equipment. Williams writes: “Food and beverage
manufacturers who acknowledge the untapped poten-
tial of optimizing their bulk bag filling systems stand to
reap considerable rewards. As the crux of efficient pack-
aging operations, state-of-the-art automated bulk bag
filling solutions can help food and beverage processors
experts involved in process manufacturing. In Processing
segments take a closer look at the top editorial content
found in Processing or on www.processingmagazine.com. EBM CORPORATE
Processing Pros segments provide high-level discussions CEO Chris Ferrell
with industry professionals on a variety of topics in the President June Griffin
process manufacturing industries. COO Patrick Rains
Ear on Processing can now be found on our website
CRO Paul Andrews
and all major podcast platforms. If you have a chance,
Chief Digital Officer Jacquie Niemiec
please give Ear on Processing a listen. If you are inter-
ested in being a guest on Ear on Processing and sharing Chief Administrative and Legal Officer Tracy Kane
your process industry expertise, please get in touch. EVP/Industrial Group Mike C. Christian

increase productivity and streamline operational costs

in a way that is sure to impact the bottom line.”
Lastly, senior editor Nate Todd speaks with Black
Diamond Regulatory Consulting president and owner
David Schoneker about titanium dioxide safety and reg-
ulation in foods and pharmaceuticals in a Q&A format.
Sincerely,
Processing (ISSN 0896-8659, print; 2641-6581, digital) is published monthly, except
combined issues in July/August and November/December by Endeavor Business Media.
Editorial and Executive Offices: 201 Main St., 5th Floor, Fort Atkinson, WI 53538. Periodicals
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address changes to Endeavor, PO Box 3257, Northbrook, IL 60065-3257. SUBSCRIPTIONS: Non-
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chemical processing, plant maintenance and safety, CHIEF EDITOR one year, $203; two year, $355. © Endeavor Business Media, 2024. No portion of this
publication may be reproduced in any form without written permission of the publisher.
josborne@endeavorb2b.com Views expressed by the bylined contributors should not be construed as reflecting the
operations and software. @ProcessingMag
opinion of this publication. Publication of product/service information should not be
deemed as a recommendation by the publisher.

Subscribe / Renew / Change of Address:

Local: 847-559-7598
Toll free: 877-382-9187
EDITORIAL ADVISORY BOARD Email: processing@omeda.com

Christine Banaszek, Sales Manager, ROSS Mixers | Frederic Baudart, CMRP, Senior Product Application Specialist, Fluke Accelix
Eric Maynard, Vice President, Jenike & Johanson | Jack Osborn, Senior Engineer, Airdusco | Colin Barbeau, Bulk Materials Handling Specialist, Hatch
Todd Smith, Manager, Kansas State University Bulk Solids Technology Center | Bill Bremer, Principal, Food Safety, Kestrel Tellevate
Robert Rogers, Senior Advisor for Food Safety & Regulations, METTLER-TOLEDO | David Brewer, Mid-Atlantic Regional Manager, Sealing Equipment Products Co. (SEPCO)
David W. Sptizer, PE, Spitzer and Boyes LLC | Mike Klimes, Applications Engineer, Tsurumi (America) Inc.

4 Processing | APRIL 2024

 APRIL 2024 NEWS, NOTES AND INSIGHTS FROM ACROSS THE PROCESS INDUSTRIES
PACK EXPO EAST CONTINUES GROWTH
TRAJECTORY WITH LARGEST SHOW TO DATE
P
ACK EXPO East recently held its larg-
est show to date, attracting 7,977
attendees and more than 500 exhibi-
tors at the Pennsylvania Convention
Center in Philadelphia from March
18-20, according to show produc-
er PMMI, The Association for Packaging and
Processing Technologies. PACK EXPO East is
a regional show for consumer packaged goods
and pharmaceutical companies to find innova-
tive solutions for their manufacturing needs.
“PACK EXPO East’s continued growth has
solidified its place as a vital event for packaging
and processing professionals in the region,” said
Jim Pittas, president and CEO of PMMI. “While
we celebrate this growth, our focus remains on
delivering the high-quality experience our shows
are known for.”
The solutions include machinery and equip-
ment, in action on the show floor, used by mar-
kets such as food and beverage, pharmaceutical,
industrial and agricultural chemical, and more.
The show also offered attendees a chance
to find crossover solutions to their most
6 Processing | April 2024
Courtesy of PMMI
challenging manufacturing needs.
In addition to the technology on the show
floor, PACK EXPO East offered educational
opportunities with the Innovation Stage and
Industry Speaks.
Attendees also had the chance to connect with
their peers at the Taste of Philly opening recep-
tion and the Packaging & Processing Women’s
Leadership Network and Young Professionals
Network receptions.
“We find that attendees enjoy opportunities to
learn about the latest industry issues while con-
necting with their peers,” said Laura Thompson,
vice president, Trade Shows, PMMI. “It gives
them a well-rounded experience that they do
not get at other industry events.”
The Innovation Stage sessions are accessible
online for registered participants until April 15.
This allows attendees who could not attend
the sessions to catch up on discussions about
groundbreaking technologies, inventive appli-
cations and proven approaches.
processingmagazine.com
MARKETS UPDATE
EPA, industry stakeholders release report
on water reuse for the beverage industry
A novel collaboration among federal and local reg-
ulators, major international beverage manufactur-
ers, non-profit organizations, consulting engineers
and water professionals recently released a white
paper titled “Advancing Water Reuse Within the
Beverage Industry.”
In the white paper, the authors explore stakehold-
er engagement, regulatory, treatment and technol-
ogy issues related to water reuse within the bev-
erage industry, along with key hurdles and near-,
medium- and long-term solutions to advance water
reuse practices at beverage manufacturing plants.
The white paper, which was released in March,
was developed under the National Water Reuse
Action Plan (WRAP), a program coordinated by the
U.S. Environmental Protection Agency (EPA).
“This work is a great first step in understanding
the regulatory and policy landscape of water reuse
and the needs specific to the beverage industry,”
said Dr. Sharon Nappier, national program leader
for water reuse of EPA.
Water is essential to the beverage industry and is
used in every facet of it, from cultivating ingredients
to dispensing and serving beverages to consumers.
Without sufficient water, beverage companies can-
not produce their products. Water supply, quality,
demand and wastewater generation are meaning-
ful in this sector. Complex water challenges have
motivated corporate personnel, regulators, consult-
ing engineers, equipment and technology provid-
ers and consumers to seek and develop solutions
to help the beverage industry optimize water usage
and operate sustainably. Toward this end, water
reuse offers a compelling opportunity for beverage
manufacturers: by recycling water for non-ingre-
dient (or non-product) purposes onsite, beverage
manufacturers can minimize water demand and
wastewater volumes, elevate operational efficien-
cies, reduce costs and achieve sustainability goals.
“Our goal is to propose solutions that are practi-
cal and achievable,” said Holly Churman, GHD ser-
vice line leader for water treatment and desalina-
tion, and a lead author of the white paper. “How can
we move the needle, and truly advance water reuse
in beverage manufacturing, in a year, two years?
Our team’s knowledgeable, well-rounded perspec-
tives informed our solutions to address important
water challenges facing the industry today”
The white paper was developed by a diverse
group of action leaders and partners under WRAP
Action 5.7, a working group of the WRAP, and
included representatives of GHD, EPA, the U.S. Food
and Drug Administration, the Idaho Department
of Environmental Quality, the San Francisco
Public Utilities Commission, PepsiCo, Inc., the
Beverage Industry Environmental Roundtable, the
WateReuse Association, the Water Environment
Federation – Industrial Water Community and
Antea Group.
The action leaders and partners identified five
priority challenges, promising solutions and tac-
tics to enable water reuse at beverage manufac-
turing plants over near-, medium- and long-term
time horizons:
• Near-term tactics involve developing a glos-
sary of terms for stakeholders in beverage
manufacturing, to improve stakeholder com-
munication and a flow chart of how to use
the Hazard Assessment Critical Control Point
framework, a risk assessment approach that
informs regulatory decision-making, for water
reuse in beverage manufacturing.
• A medium-term strategy includes organizing
outreach events, such as summits, focused spe-
cifically on water reuse in beverage manufactur-
ing to help resolve public perception issues.
• Another medium-term tactic is to develop a
technical guidance document to inform treat-
ment and monitoring designs, abating some
engineering challenges resulting from current
regulatory gaps.
• In the long term, commissioning intention-
al demonstration plants to test ideas and
inform industry best practices can clarify
important decision points and enable the
uptake of water reuse systems at beverage
manufacturing plants.
2402PRO_CheckAllValve.indd 1
“The WateReuse Association is proud to help lead
this important work to advance opportunities for
water reuse in the beverage industry,” said Patricia
Sinicropi, executive director of the WateReuse
Association. “Advancing water reuse in new indus-
tries requires convening diverse, collaborative
teams of stakeholders to find solutions to complex
challenges. This white paper helps chart a path for
more fit-for-purpose water recycling and more resil-
ient and sustainable business practices within the
food and beverage sector.”
COMPANY NEWS
Tyson Foods opens new food
production facility in Kentucky
Tyson Foods, Inc. recently opened a new $355 mil-
lion food production facility in Bowling Green,
Kentucky. Built to support a significant expansion
of its bacon production capabilities, the new plant
positions Tyson Foods to capitalize on its cate-
gory leadership and the increasing market for
its products.
The 400,000-square-foot plant is expected to pro-
duce two million pounds a week of premium quali-
ty Jimmy Dean and Wright Brand bacon retail prod-
ucts and bacon used in foodservice. This plant will
help the company meet the needs of this category
now and as it grows in the future.
“Our innovative new plant in Bowling Green
reflects a major investment that we are proud to
make in south central Kentucky,” said Donnie King,
president and CEO, Tyson Foods. “This enables us
to focus on the health and safety of our team mem-
bers while also delivering best-in-class service for
our customers.”
Avista Technologies, Inc.
celebrates 25th anniversary
Avista Technologies, Inc., a global brand of Kurita,
is celebrating its 25-year journey marked by innova-
tion, dedication and excellence in pioneering mem-
brane treatment technologies. From its humble
beginnings in San Marcos, California, in 1999, Avista
has evolved into a premier provider of membrane
treatment solutions worldwide, offering a wide vari-
ety of products and services and serving customers
in over 100 countries.
The unwavering commitment of Avista’s employ-
ees, customers and partners has been instrumen-
tal in driving continuous innovation to meet the
dynamic demands of the membrane treatment
industry. Avista is known for the introduction of
disruptive technologies such as a “green” chemical
product line (2006), Chromatic Elemental Imaging
(2013) for organic foulant identification, Avista
Black Box (2014) for remote troubleshooting, Avista
Advisor Ci (2015) chemical dosing with complex
ion technology, Avista Center of Excellence (2021),
and the AvistaClean MF/UF product line (2023) to
improve pretreatment results. The integration as
a global brand of Kurita in 2019 and the seamless
leadership transition from co-founder Dave Walker
to Toshi Maema in 2023 further underscore Avista’s
journey of growth and evolution.
“Since I joined Avista a year ago, I’ve seen the
truly impressive relationships our teams have
formed, some lasting for a quarter of a century. The
company has a remarkable history, from its modest
origins to its current position," said Maema, Avista’s
CEO and president.
Send news and events for consideration
to josborne@endeavorb2b.com
April 2024 | www.processingmagazine.com 7
1/12/24 7:40 AM
 COLUMN: ASSET MANAGEMENT

DRIVING EFFICIENCY:
STRATEGIES FOR LAUNCHING
AND SCALING APM SOLUTIONS
By Pratibha Supported by the right strategy and roll-out, asset performance management
Pillalamarri solutions can improve equipment and process efficiency within a short timeframe.
Aspen Technology

P
Pratibha Pillalamarri is the
rocess manufacturers are facing heightened pres- health that can very quickly be turned into efficiency
senior product marketing
sure to squeeze more out of their plant operations improvements. For instance, the knowledge gained from
manager, APM at Aspen
amid challenges such as a shortage of skilled labor, prescriptive APM solutions can lead to early and actionable
Technology, Inc. Pratibha joined
tightening budgets and an increased focus on sus- insights that prevent costly disruptions. Disruptions can be
the AspenTech APM product
tainability. In this landscape, operational efficiency anything from equipment breakdowns and product loss to
marketing team in December,
emerges as one of the main drivers of digitalization energy inefficiencies and excess inventory. To put it sim-
2020. She has more than 15
initiatives, presenting an opportunity for organizations to dem- ply, APM solutions with prescriptive capabilities ensure that
years of experience across
onstrate impact and maximize returns on digital investments. maintenance is performed exactly when it is needed, at the
different industries in various
Asset performance management (APM) solutions play a piv- most cost-effective point.
capacities: in technical services,
otal role in enhancing operational efficiency. These solutions While these initiatives have grown more strategic and
as a process engineer and as
provide early warnings to minimize process disruptions and mature in recent years, navigating where and how to start
a senior project manager. In
ensure optimal asset performance, thereby setting the stage remains a challenge. Supported by the right strategy and roll-
her current role Pratibha uses
for broader innovation and sustainability initiatives. out, APM solutions can improve equipment and process effi-
her diverse experience to
APM can be an effective digitalization gateway, in part, ciency within a short timeframe. Today’s industry leaders
understand customer issues and
because of its ability to help maintenance and operations are following a series of steps to set their organization down
connect them to cost effective,
teams gain real-time visibility into process and equipment the right path:
AI-powered asset performance
management solutions. She has
a master’s degree in chemical
engineering from the University
of Houston, a master’s degree
in process engineering and an
MBA from Hamburg University
of Technology, and bachelor’s
degree in chemical engineering
from the University of Madras.

35938549 © Photographerlondon | Dreamstime.com

8 Processing | April 2024

Find the right partner
When searching for an APM provider or solution,
organizations should look for partners with indus-
try-specific domain knowledge, as well as a shared
understanding of industrial processes and the pro-
cess manufacturer’s unique needs. The best partner-
ships are grounded in collaboration and feedback
offering post-implementation support, a commit-
ment to continuous innovation and open channels
of communication.
Gain buy-in across the organization
To get the most out of a new APM deployment,
operations managers should take into account
what it will mean for everyone, from the plant floor
to the executive suite, and develop a phased roll-out
plan accordingly.
Vision workshops are a useful tool in which key
stakeholders can contribute. They help identify
areas or units in the plant most vulnerable to pro-
cess disruptions, define key performance indicators
(KPIs) crucial for the rollout’s success and designate
champions within the organization to spearhead
the new APM deployment.
Aggregate the right data
Gathering the right data sources is also an impor-
tant step in facilitating high levels of collaboration
"The best partnerships are grounded in collaboration and
feedback offering post-implementation support, a commitment
to continuous innovation and open channels of communication."
and accuracy. The most successful APM solutions and achieve their larger digital ambitions. Starting
aggregate data from diverse sources, including small and learning from initial implementa-
sensors, yield metrics and product quality param- tions enables plant managers to naturally build
eters, to enable real-time process and equip- expertise to support more advanced implemen-
ment monitoring. tations and new KPIs, such as avoided environ-
mental risks.
Identify and track progress In conclusion, a well-defined long-term digital
Ongoing tracking of KPIs, which should be based strategy is essential for process manufacturers to
on a well-thought-out value-capture strategy and successfully deploy, integrate and scale technolo-
an active communication and management plan, gies across their operations. This strategy, rooted
maintains stakeholders’ focus on both short-term in clear objectives aligned with broader business
objectives and long-term success. As part of the goals and supported by comprehensive metrics
roll-out plan, operations leaders can also identi- and benchmarks, ensures a focused and effec-
fy periodic checkpoints to ensure KPIs are being tive deployment. By prioritizing strategic imple-
met and opportunities to scale APM solutions are mentations and leveraging the right APM solu-
being identified. tion, organizations can swiftly realize efficiency
gains, driving operational excellence and sus-
Start small but think big tained growth.
By prioritizing specific workstreams and critical
equipment first, process manufacturers can lever- Aspen Technology, Inc.
age APM as a sure-fire way to improve efficiency www.aspentech.com

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2403PRO_DynamicAir.indd 1 April 2024 | www.processingmagazine.com 9

2/6/24 1:34 PM
 P R O D U C T

FOCUS
BUTTERFLY VALVE
The Type 565 Lug-Style Butterfly Valve from GF
Piping Systems completes the Type 565 portfolio
of lightweight, corrosion-free options for water
transport and water treatment applications. The
Send products for consideration in this lug-style design is highly suitable for use as an
section to josborne@endeavorb2b.com end valve, permitting one-sided disassembly.
Like the Type 565 Wafer, the Type 565 Lug is
designed to directly compete with metal valves.
Offering corrosion and abrasion resistance while
being lighter than metal equivalents, both the
565 Wafer and 565 Lug exist as cost-effective
alternatives. Compatibility with other GF automa-
tion components (such as pneumatic, electric
or smart actuators and positioners) allows for
seamless integration into an automation loop.
Further, GF’s 565 valves carry an Environmental
Product Declaration (EPD) as well as numerous
marine and water approvals.

GF Piping Systems
www.gfps.com

ACOUSTIC PARTICLE MONITOR

Emerson recently announced the release of the Rosemount SAM42 Acoustic Particle
Monitor for measuring the amount of entrained sand in the output from oil and gas
wells. The monitor can detect extremely low concentrations of entrained sand in
challenging conditions with a high level of measurement repeatability and sensitivity.
Accurate real-time data helps minimize erosion risk, allowing producers to maximize CHEMICAL METERING AND DOSING PUMP
throughput without compromising asset safety. An all-in-one design features onboard
Watson-Marlow Fluid Technology Solutions recently launched the Qdos H-FLO
data processing, explosion-proof protection and simple installation with no pipe pen-
chemical metering and dosing pump, designed specifically for higher flow
etration needed. The Rosemount SAM42 is available in two versions that are designed
rates up to 158 gallons per hour (600 L/h). Qdos H-FLO delivers the same
to accommodate pipe surface temperatures between -40°F (-40°C) and 554°F (290°C),
outstanding accuracy and reliability as other Qdos pumps but for higher
making it suitable for oil and gas applications and geothermal energy production. It
flow rates with a variety of pumpheads and a range of different tube materi-
can be mounted on pipes with diameters between 2 and 48 inches and is rated for use
als to ensure chemical compatibility with the process fluid. The Qdos H-FLO
in hazardous areas with Ex d (Flameproof) approvals, including ATEX, IECEx, USA and
high-precision pump offers flexibility to be scalable with a customer’s process,
Canada; and Ex i (Intrinsic Safety) approvals, including ATEX and IECEx.
whether it is in water and wastewater treatment, mining and mineral pro-
Emerson cessing, chemical applications in food and beverage, or pulp and paper. The
www.emerson.com release of Qdos H-FLO enhances the range of Qdos pumps by offering flow
rates up to 158 gallons per hour (600 L/h) and pressure capability up to 102
psi (7 bar). Like the rest of the Qdos range of peristaltic pumps, Qdos H-FLO
cuts costs through higher precision chemical metering, with an accuracy of
±1% and repeatability of ±0.5% in dosing.

Watson-Marlow Fluid Technology

www.wmfts.com

10 Processing | APRIL 2024

 NEW PRODUCTS

PRESSURE REGULATOR VANTON THERMOPLASTIC PUMPS

ControlAir LLC recently introduced its new Type
410 High Precision Pressure Regulator. The Type It’s What’s Inside that Counts
410 provides a high level of regulation accuracy
and repeatability during variable operating condi- Every Vanton pump
tions. Designed with precision and reliability in limits fluid contact to
mind, the Type 410 serves as a cost-effective yet component parts that
highly efficient solution for controlling industrial
are injection molded
processes. Despite its superior performance, the
or fabricated of
Type 410 remains an economical choice, making
chemically inert, CGM-ANSI
it perfect for high-volume OEM applications where
cost-effectiveness is paramount. With its superior homogeneous MAG DRIVE
regulation characteristics, the Type 410 consis- thermoplastics, or other
tently meets control requirements, even amidst non-metallic materials
fluctuating operating conditions. Built to withstand selected for your specific
the harshest industrial environments, the Type 410 application.
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2404PRO_VantonPumpAndEquipmentCorp.indd 1 3/7/24 4:16 PM
 POWDER & BULK PROCESSING
ROTARY DRYER
OR FLUID BED?
LET THE OPERATION DECIDE
The best dryer type for a given project often depends on how
each dryer’s operation will impact the material and facility.
By Nick Reckinger, FEECO International
W
hether producing fillers, interme-
diary materials, or end products,
an industrial drying step can be
found in nearly every facility pro-
cessing bulk solids. Producers rely
on industrial drying systems to pre-
pare material for use as a feedstock, as a finishing
step in the production process, and more.
Often working to meet stringent quality stan-
dards and tight deadlines against small profit mar-
gins, producers require their drying systems to be
efficient, reliable, and able to consistently produce
material according to specification.
Both rotary dryers and fluid bed dryers can
meet these objectives, which can make the choice
between the two types unclear in some settings,
particularly given the amount of overlap in appli-
cations historically seen. However, with each
dryer type offering distinct differences, the choice
between them often becomes clear when consid-
ering how each dryer operates. The resulting impli-
cations on the material and facility will often influ-
ence the decision of which dryer type to select.
Note: While indirect rotary dryers are available on
the market, they are less common than direct rotary
dryers and are not often compared with fluid bed dry-
ers. As a result, the information provided in this article
on rotary dryers is specific to the direct configuration.
Rotary dryer operation
A rotary dryer uses gravity and motion, com-
bined with air flow, to move material through
the unit. Material is passed through a horizon-
tally rotating cylinder (the “drum”), which is
set on a slight angle to encourage movement of
material through the drum. Combustion gases
are simultaneously passed through the unit at a
predetermined velocity.
As the drum rotates, flights, or material lift-
ers, pick up material and drop it through the air
12 Processing | APRIL 2024
stream, creating a “curtain” of cascading mate-
rial in the drum’s cross section that maximizes
heat transfer between the material and the
process gas. Combustion gases may be passed
co-currently (parallel) or counter-currently to
the material.
Fluid bed dryer operation
Unlike rotary dryers, which employ mechanical
motion, fluid bed dryers are considered a type
of pneumatic dryer, meaning that air flow alone
moves material through the unit.
A fluid bed dryer consists of an enclosed vessel
through which a predetermined velocity of air is
passed from the bottom up via a perforated plate,
causing the bed of bulk solid material to become
suspended and behave in a fluidized state. Each
particle is surrounded by air, making this approach
to drying very thermally efficient.
How dryer operation influences dryer selection
By understanding how each dryer operates, one
can begin to make decisions about what applica-
tions might be suitable for one type over the other.
This is particularly evident when considering
the following:
Energy consumption
The way each dryer operates has a significant
influence on the amount of energy required.
Since fluid bed dryers rely on being able to sus-
pend the material in the air flow, applications
involving materials with large particle sizes or high
bulk densities may require too much energy in a
fluid bed dryer to be economically practical.
As such, materials with high bulk densities or
larger particle sizes (greater than 1/2 to 1 inch) are
typically better served by a rotary dryer, which
instead uses mechanical motion to put material in
contact with the air stream.
 Rotary dryers contain flights, or material lifters, that pick up and drop
the material through the air stream as the drum rotates, maximizing heat
transfer between the material and the process gas.
All images courtesy of FEECO International
It is also important to note that because a cer-
tain amount of energy is required to reach mini-
mum fluidization, a savings in energy is not appli-
cable when running a fluid bed dryer at reduced
capacity. In contrast, a rotary dryer does not
require as much energy to dry lesser quantities
of material, so producers can garner some energy
savings when running at reduced capacity.
Thermal efficiency
A long-held myth often encountered in the indus-
try is that the higher thermal efficiency of fluid bed
dryers translates to lower fuel costs. Their high
thermal efficiency does account for some savings
in fuel, but that savings is negated when consider-
ing that they typically use lower inlet gas tempera-
tures than rotary dryers.
Some savings in energy can be garnered in
fluid beds by employing recirculated air from the
exhaust gas system. However, this approach must
be carried out with care; the use of recirculated air
will also require some type of dust collection to
avoid plugging the ductwork and the perforated
plate. Recycled exhaust gas may also be slightly
higher in moisture content, requiring higher prod-
uct and exhaust gas temperatures to achieve the
desired result, again, negating the thermal effi-
ciencies gained.
When the totality of energy use and thermal effi-
ciency is considered, these two dryer systems are
comparable in fuel costs and energy consumption.
Material action in the dryer
Operation also influences material action, which
can be an important consideration in some set-
tings. Operation impacts both the action between
particles and the action between particles and the
dryer’s interior.
Rotary dryers pick up and drop material through
the air stream, so materials that must not suffer
degradation or that are particularly fragile may not
be suited to this type of dryer.
When degradation is not a concern, or where
granules have a suitable green (wet) strength,
the tumbling action that occurs in the bed of the
rotary dryer can offer an advantage by polishing
granules. When processing rounded granules, this
action helps to further round and refine the prod-
uct. When working with jagged, irregular granules,
such as those produced via compaction granu-
lation, the tumbling action can knock off loose
edges and reduce the amount of attrition in the
final product.
Because they are not dropping material, fluid
bed dryers inherently promote less material deg-
radation, offering a gentler drying option, though
some degradation is still possible due to the inter-
action between particles during fluidization.
Operational stability
The ability to reach fluidization relies on parti-
cles falling within a tight range of specifications,
meaning that fluid bed dryers are often not suit-
able at plants where variation in feedstock mois-
ture content, particle size, or otherwise, is pos-
sible. Such variation in particle characteristics
quickly leads to process upsets when working with
fluid bed dryers.
Rotary dryers, on the other hand, are much more
tolerant of feedstock variation. Though it is impor-
tant to note that feedstock uniformity should still
always be a top priority, slight variation in particle
size, moisture content, etc., will not lead to process
upsets with a rotary dryer.
Operational stability also plays into the down-
time and labor requirements associated with
cleaning the unit. If a fluid bed dryer is shut down
with an active bed, the bed will collapse, and
material will fall through the distributor plate.
This action, and the resulting mess, is referred to
as “weep.” The area below the distributor plate will
then require cleaning before operation can resume.
Conversely, a rotary dryer shut down during
production can simply be restarted, so facili-
ties expecting frequent shutdowns may be better
served by rotary dryers.
Ease of operation
In addition to a uniform feedstock, proper fluidi-
zation also requires a careful balance of air flow
and system pressures to maintain adequate fluidi-
zation, as well as to avoid short circuiting (a term
used to describe when the product consists of
both fully dried and undried material).
For these reasons, fluid bed dryers require more
supervision; operators need a more advanced
understanding of the unit and their production
line and must carefully monitor the operation to
prevent upsets and ensure that the finished prod-
uct consistently meets specification.
Capacity
The inherently larger size of rotary dryers means
they are capable of handling higher throughputs
than fluid bed dryers. This is essential for high-
capacity production facilities but may be overkill in
settings requiring something smaller, where a fluid
bed dryer would be a more practical approach.
For facilities in which the fluid bed dryer is
applicable and capacity requirements are within
its range, the fluid bed dryer is the obvious choice,
offering a cost-effective option.
Dryer infrastructure/Facility requirements
The supporting systems and other facility-related
factors may also influence dryer selection.
Available space
Assuming that the fluid bed can meet capacity
requirements, facilities working with limited space
will often select a fluid bed dryer, due to its much
smaller footprint.
APRIL 2024 | www.processingmagazine.com 13
 FUTURE PROOF CHILLERS
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 In a fluid bed dryer, air is passed through the material from the bottom up via a
perforated plate, which fluidizes the material and provides very thermally efficient drying.
Off-gas treatment and particulate capture
Both dryer types require exhaust gas treatment and particulate capture. The
larger air volume required to achieve fluidization, however, necessitates a larg-
er off-gas treatment system.
There is also a greater potential for fine material to be carried away by the
exhaust gas system with a fluid bed dryer, requiring more robust particu-
late capture (typically a baghouse and/or cyclone separator) compared to a
rotary dryer.

Maintenance
Though they are still considered relatively low-maintenance, because rotary
dryers have more moving mechanical components, they require a bit more
maintenance compared to fluid bed dryers.

CAPEX and OPEX

Not surprisingly, the project budget also has a significant influence on the
decision between dryer types.
Fluid bed dryers are a lower-cost option, making them ideal for smaller-scale
operations, but as has been demonstrated, they are not always a fit. Further,
the additional labor requirements, greater potential for downtime, and other
factors have the potential to inflate operating costs.
While rotary dryers come at a higher price point, they are often favored for
their simple and reliable operation.
All of these factors are important considerations that must be balanced in
evaluating the CAPEX and OPEX associated with each dryer type.

Thermal Care’s efficient chiller Concluding remarks

solutions, with the latest refrigerant
technology, will keep your business
moving forward.
Both rotary and fluid bed dryers offer an effective, efficient approach to drying
a wide range of bulk solids. Despite their overlap in capabilities, however, the
best dryer type for a given project can often be best determined by considering
how each dryer’s operation will impact the material and facility. Those unsure
of which system will suit their application best should work with a qualified
OEM to guide their decision.

Nick Reckinger is a process sales engineer at FEECO International, a supplier of custom process equipment,
REFRIGERANT FAQ
process development services, and service support to the global industrial processing industry.
888-387-9725
sales@thermalcare.com FEECO International
www.thermalcare.com www.feeco.com

14 Processing | APRIL 2024

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 POWDER & BULK PROCESSING
BULK BAG FILLER
UPGRADES TARGET
THE BOTTOM LINE
Best practice strategies to help food and beverage
processors increase productivity and profit by upgrading
critical bulk bag filling equipment. | By Del Williams
M
anufacturers in the food and bever-
age sector continually seek methods
to boost their operational efficiency
and are prepared to invest in superior
machinery when the expected returns
justify the expenditure. However, the
potential advantages of upgrading bulk bag filling
systems are frequently underestimated.
16 Processing | April 2024
In food and beverage processing, bulk bag filling
stations play a pivotal role in ingredient packaging,
enhancing the speed and efficiency of the packing
procedure. With an array of models available, these
systems range from hand-operated setups to semi-
automated units. Semi-automated fillers can signifi-
cantly increase productivity and the bagging rate by
automatically introducing a pallet to the machine
 By integrating advanced bulk bag filling equipment,
companies can realize substantial gains in productivity.
All images courtesy of Spiroflow
and removing filled bags, reducing the time required
to manually handle every pallet and filled bag.
While many systems enhance the speed of bag-
ging operations, there is a continual opportunity to
refine and improve efficiency and output. By inte-
grating advanced bulk bag filling equipment, com-
panies can realize substantial gains in productivity
by increasing the number of bags filled per hour,
allowing more product to fit in existing bags, and
even facilitating a transition to smaller bag sizes.
“These types of upgrades can substantially reduce
operating costs, increase production through-
put, reduce shipping costs, and even help proces-
sors recover lost revenue,” says Don Mackrill of
Automated Handling Solutions (AHS), which pro-
vides engineering solutions that incorporate spe-
cialty conveyor, material handling, and automation
equipment technologies.
Within the portfolio of solutions offered by AHS
is Spiroflow, which offers a comprehensive range of
bulk filling and discharging equipment, including
bulk bag fillers, bulk bag unloaders, and addition-
al equipment needed for automated bulk handling
of materials.
 Mackrill, a material handling and system integra-
tion expert, offers some key advice that can help to
cost-effectively optimize the bulk bag filling process.
Improve weighing accuracy
to recover lost revenue
Products sold by weight must be filled to the adver-
tised weight. To avoid the possibility of underfilling,
manufacturers frequently opt to fill packages more
than necessary, which results in lost revenue that
can accumulate over time. Inconsistent fill weights
only increase potential losses.
“Processors don’t get paid for the extra pounds
they overfill the bag. If they can improve the weigh-
ing accuracy, they are not giving away as much free
product,” says Mackrill.
Switching to a bulk bag filler that offers precise
weighing accuracy can effectively resolve this issue.
“If you can improve the weighing accuracy of your
current bulk weighing system from +/- 5 pounds to
+/- 1 pound, you are no longer overfilling as much.
From an accounting perspective, that is recov-
ered revenue that goes right to the bottom line,”
says Mackrill.
When the bagging rate exceeds 30 to 35 bags per
hour, pre-weighing the material in a hopper above
the filler should also be considered.
“Pre-weighing the ‘shot’ of material while a bag
is being densified and removed from the system
and the next bag is rigged, significantly increas-
es the bagging rate,” says Mackrill. He notes that
some bulk bag filler systems such as the CTE from
Spiroflow are capable of filling more than 40 bags
per hour if the material is pre-weighed.
To further enhance the precision of weighing, it
is important to consistently fill hoppers with equal
amounts of material and align this process with the
 When processors use
a bulk bag filler that offers
precise weighting accuracy,
they are not giving away
as much free product.
pace of bagging operations. Even minor factors such
as the volume of material in the silo that feeds the
hopper can upset the timing.
“As the weight of the material in the silo decreases,
so does the flow rate, which makes it difficult to pre-
dict how fast product is going to come out,” explains
Mackrill. “If you can consistently match the convey-
ing rate into the hopper with the bagging rate, then
you can dial in a very tight weighing accuracy.”
Compacting material
more efficiently pays dividends
Upgrading bulk bag filling equipment to a more
efficient system that can compact or densify the
material in each bag offers significant cost-saving
opportunities. One effective strategy for reducing
packaging costs is to efficiently increase the den-
sity of the product in each bag. By doing so, it may
be possible to purchase smaller bulk bags while still
shipping the same quantity of product.
On the other hand, for powders with bulk den-
sity less than 25 to 30 lbs/ft3, it may be possible
to increase the product capacity within the exist-
ing bag size. This allows food and beverage proces-
sors to consistently approach the maximum weight
restrictions permitted on truck trailers and avoid
 Upgrading bulk bag filling equipment to a more efficient system that can compact
or densify the material in each bag offers significant cost-saving opportunities.
additional shipping expenses incurred when the
weight falls below the limit.
Maximizing the amount of product in existing
packaging dimensions can lead to increased pro-
duction efficiency, potentially reducing the time
required to operate the production line to achieve
the desired quantity of goods. Any surplus capaci-
ty can be used to accommodate increased demand
and support the sale of additional products.
Mackrill notes that enhancing material densifica-
tion leads to a “ripple effect” of savings.
“You’ll weigh out every trailer and over time
fewer trailers will be required to transport the
total product weight within a specific timeframe.
Additionally, the increased capacity of each bulk
bag results in filling fewer bags, thereby reducing
packaging costs,” explains Mackrill.
Another benefit is improved bag stability. Some
dry materials will entrap or entrain air between
the particles more than others, and those that do
require more vibration or densification to drive out
the air between the particles. When that air is not
driven out, the bulk bags can become unstable and
tip and fall during transport, handling, or storage.
This can put operators at risk of injury, damage
product, and increase operational costs.
April 2024 | www.processingmagazine.com 17
 “Unstable bulk bags can topple off a pallet while
being moved by forklift or can lean or slump over in
a truck trailer as it bounces down the road, making
unloading difficult and even posing a safety hazard,”
says Mackrill, adding that the primary purpose of a
bulk bag filling machine is to “produce a safe and
stable bulk bag.”
To improve bulk bag stability and safety, some
equipment is specifically designed to compact dif-
ficult fill material such as powders, granules, or
flakes that are easily aerated. The CTE bulk bag fill-
er from Spiroflow, for example, utilizes patented
cone table densification that deaerates the mate-
rial with a flattened angle of repose, resulting in a
very safe and stable bag.
The speed at which powders are compacted in
the bag also impacts productivity.
“If it takes you twenty minutes to vibrate through
the pallet into the bag [with your current machine] to
the point where you can safely handle it, replacing it
with a machine that can do the same in two minutes
dramatically improves productivity,” says Mackrill.
Consider streamlining the
conveyors that feed the filler
Increasing the productivity of bulk bag fillers may
require an upgrade or redesign of the conveyor sys-
tem that transports products to the fillers.
However, it can be difficult to select the optimal
mechanical conveyor system. This is the case when
purchasers are relatively uninformed about the spe-
cific attributes and advantages unique to each con-
veyor type available on the market.
The most critical aspect to consider is the type
of product that the processor is trying to convey.
18 Processing | April 2024
Issues such as product flowability, abrasiveness
and cohesiveness should always be considered,
whereas product degradation or the need to main-
tain a blend may be key aspects to consider in
some applications.
For food-grade applications, hygiene specifica-
tions and the ability to clean-in-place are impor-
tant considerations.
According to Mackrill, there are several catego-
ries of enclosed conveyors that meet these require-
ments, including aero mechanical, flexible screw,
and tubular cable drag designs.
“Conveyors are almost always part of an integrat-
ed system with fillers because as soon as you get
material in or out of the bag, you need to take it
somewhere. We want to do that in a fully enclosed
environment so that we’re not letting dust out into
the plant, not losing product, and not leaving the
conveyor open to humidity or rain [if some of the
conveyor is outdoors],” says Mackrill.
Still, every material handling scenario is unique.
Dealing with difficult powders or delicate, sticky
products presents its own set of challenges.
To resolve these issues, food processors can ben-
efit from the guidance of expert powder conveying
integrators that have implemented various equip-
ment types in complex applications over decades.
An experienced integrator can not only help a pro-
cessor select the best type of conveyor for their
application but also optimize it for their specific
type of food and process. Spiroflow has a wealth of
experience consulting on these matters and offers
enclosed aero mechanical and flexible screw convey-
ors, as well as tubular cable drag conveyer systems
from another AHS company, Cablevey Conveyors.
 Conveyors are almost always part of an integrated
system with fillers because as soon as you get material
in or out of the bag, you need to take it somewhere.
 In food and beverage processing, bulk bag filling stations
play a pivotal role in ingredient packaging, enhancing the
speed and efficiency of the packing procedure.
“Tubular cable drag conveyors are going to be
extremely gentle. Our aero mechanical convey-
ors are a little harder on product, but extreme-
ly quick. Flexible screw conveyors are very cost
effective in getting product from point A to point
B,” says Mackrill.
To ensure optimal results, Mackrill recom-
mends rigorous testing of powders. Food and bev-
erage producers are invited to submit their prod-
ucts for analysis to assess the materials’ flow
characteristics.
Food and beverage manufacturers who acknowl-
edge the untapped potential of optimizing their
bulk bag filling systems stand to reap consider-
able rewards. As the crux of efficient packaging
operations, state-of-the-art automated bulk bag
filling solutions can help food and beverage pro-
cessors increase productivity and streamline oper-
ational costs in a way that is sure to impact the
bottom line.
Del Williams is a technical writer based in Torrance, California. For
more information: call 704-215-2624; email sales@spiroflow.com; or
visit www.spiroflow.com.
Spiroflow
www.spiroflow.com
Setting the Standard in
Fluid Bed Dryers
Experience Unrivaled Efficiency and
Precision Drying Technology.

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carriervibrating.com

A Division of
 POWDER & BULK PROCESSING
P R O D U C T

FOCUS
Cone crusher
Nordberg HP350e cone crusher for the aggregates and
mining industries offers enhanced performance, higher
uptime, easier and safer maintenance, and a series of
other improvements over previous models. Performance
Send products for consideration in this improvements include enhanced kinematics and more
section to ntodd@endeavorb2b.com efficient chambers for up to +10% performance in second-
ary and tertiary application (as compared to HP300). Unit
features no-backing liners for quick, easier and safer liner
change; head anti-spin brake for extended liner wear
life; optional ring bounce monitoring for active overload
protection; and a new feed cone lifting tool for safe lifting
and handling. System offers three alternative kinemat-
ics to choose from, alternative speeds, and 10 innovative
application-specific no-backing chamber designs for
secondary, tertiary and quaternary stages. Aftermarket
support is fully covered as most parts are common be-
tween the earlier HP300 design and HP350e, and the rest
remain either interchangeable or upgradable.

Metso
www.metso.com

High-capacity batch sifter

Kason KR3020-SS high-capacity batch sifter features a unique rectangular
design, specifically tailored for high-efficiency industrial sifting. Rectangular sifter
is designed to be mounted on top of a mixer or hopper to provide a sanitary, gap-
free solution for food-grade applications, and features a convenient bag-cutting
shelf design to assist operators rip and tip. Unit is capable of managing high- Cloud-based yard management software
capacity processing and incorporates a magnet drawer beneath the screen to
Schenck Process LOGiQ yard management cloud-based software system
capture ferrous materials, further guaranteeing product purity and safety. Sifter’s
combines smooth and efficient truck loading operations with fully automated
single-motor design reduces power consumption and streamlines maintenance,
weighing of bulk materials and is supported by the company’s LOGiQ log-on
and its counterweighted lid ensures easy and safe operation. Unit is compact,
terminals. System is a proven solution for the cement and steel industry but is
making it suitable for smaller enterprises or those where space is at a premium
also suitable for yard management in other segments of industrial produc-
and is shipped with a dust control port for integration with existing dust collection
tion. Solution handles all logistical steps from the entry of an authorized
systems. Screens come in various mesh sizes, ensuring flexibility and suitability
truck onto company premises to the exit in a seamless process. Software
for a wide range of material types and sizes.
system monitors and controls access, supports weighing processes, ensures
Kason correct loading and records all relevant data without delays. All information is
www.kason.com integrated into the ERP system, for example SAP, to provide up-to-date sales
and administrative data. Access is controlled via LOGiQ registration terminals,
which are intuitive to use and available in several languages on request.
Processes run automatically without the need for manual staff intervention,
reducing the susceptibility to errors and increasing safety.

Schenck Process
www.schenckprocess.com

20 Processing | APRIL 2024

Revolutionize Your Drying Process
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A Division of
 POWDER & BULK PROCESSING

22 Processing | APRIL 2024


DAVID SCHONEKER
PRESIDENT / OWNER,
BLACK DIAMOND
REGULATORY CONSULTING
David Schoneker is president and
owner of Black Diamond Regulatory
Consulting, an independent firm
specializing in providing regulatory
and quality consulting for the
pharmaceutical, dietary supplement,
food, and related industries.
Q+A:
TITANIUM DIOXIDE
SAFETY AND REGULATION
IN FOODS AND PHARMACEUTICALS
Ongoing efforts to ban the ubiquitous pigment TiO2 do not align with
recent statements from international regulatory agencies.
T
itanium dioxide (TiO2) has been widely
used for decades as a colorant in cos-
metics, medicines, and foods due to its
bright white color and opacity. In 2022 the
European Commission banned the use
of TiO2 in foods and dietary supplements based
on concerns raised by the European Food Safety
Authority (EFSA).
In a May 6, 2021, post on the authority’s web-
site, the chair of its Panel on Food Additives and
Flavourings is quoted as saying, “Taking into
account all available scientific studies and data,
the panel concluded that titanium dioxide could
no longer be considered safe as a food additive. A
critical element in reaching this conclusion is that
we could not exclude genotoxicity concerns after
consumption of titanium dioxide particles. After
oral ingestion, the absorption of titanium dioxide
particles is low; however, they can accumulate in
the body.”
This EU ban could potentially extend to include
the use of TiO2 in pharmaceuticals as early as
next year as well.
Processing recently spoke with David Schoneker,
president and owner of Black Diamond Regulatory
Consulting, about the EU ban and the regulatory
outlook for TiO2 in the US and around the world.
Black Diamond Regulatory Consulting is an inde-
pendent firm specializing in providing regulatory
and quality consulting for the pharmaceutical,
dietary supplement, food, and related industries.
(Editor's note: This conversation has been edited
for space and clarity.)
Q: You coauthored a position paper published
earlier this year by the Product Quality
Research Institute (PQRI) arguing that the sci-
ence does not support the EU’s concerns about
the potential risks of titanium dioxide. What did
the EFSA get wrong in its evaluation? And what
does the science say about the safety of titanium
dioxide in foods and pharmaceuticals?
A: They focused their evaluation on nano grades
of TiO2 that have nothing to do with the food
and pharmaceutical grades that we all use and
have been exposed to for a hundred years. The
nano grades are special grades of TiO2 that pri-
marily have been engineered for things like cata-
lyst use. None of the nano grades are used as a
pigment in foods and drugs because they’re too
small to have any coloring properties. Part of the
reason EFSA did that is that the grades for foods
and drugs have always contained a certain por-
tion of nanoparticles as part of their particle size
distribution. They’ve been there forever, we’ve all
been exposed to them, probably every day of our
lives when we’ve eaten foods and drugs that con-
tain TiO2. And not once has anybody ever found
an adverse event that was tied to the use of food
and drug grade TiO2.
In Europe, and particularly in France, there is a
lot of concern about nanoparticles. This got into
the discussion in ways that I don’t believe were
really based on good science, but it focused EFSA’s
attention on the nano grades. And on some of
the nano grades, there were outstanding data
gaps. There aren’t data gaps on the food and drug
grades, but EFSA deprioritized the food and drug
grades in their assessment and focused on these
uncertainties about nano grades.
Many regulators and experts around the
world have looked at these studies and the EFSA
Opinion and come to completely different conclu-
sions about the science. In fact, numerous addi-
tional studies have come out designed to answer
the questions on the nano grades, and these
APRIL 2024 | www.processingmagazine.com 23

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"There is no good alternative for Ti02 that has the
properties we need, not only for food and dietary
supplements, but even more so for pharmaceuticals."
studies have all shown that, even with the nano
grades, there are no genotoxicity issues.
Q: Your PQRI position paper also discusses the
implications of a TiO2 ban in pharmaceuti-
cals sold in the EU. How would such a ban impact
the pharmaceutical industry and its ability to sup-
ply critical medicines to patients and consumers
in Europe and beyond? What’s different about
a pharma ban compared to a ban in foods and
dietary supplements?
A: There is no good alternative for TiO2 that has
the properties we need, not only for food and
dietary supplements, but even more so for pharma-
ceuticals. The primary property that gives TiO2 its
benefits is that it’s a very opaque material. Calcium
carbonate is probably the best substitute but has
nowhere close to the opacity of TiO2. So, any refor-
mulation effort is going to be extremely difficult
and not even possible for some drug products.
In Europe alone, there are 91,000 drug products
that contain TiO2 that would have to be reformu-
lated if there were to be a ban on pharmaceutical
uses in Europe. If there really was a safety concern
with TiO2, everybody would say, “We have to do
what we have to do, and we’ll make the best of it.”
But since there really isn’t any safety concern, this
question of reformulating 91,000 drug products
really comes into play.
Many APIs (drugs) are very light sensitive, and
one of the main reasons you put a coating on a
tablet is to protect the API from light. With a TiO2
coating, generally you’ll be able to achieve opacity
with about 3% weight gain from the film coating.
To get a similar, though not as good, coating with
an alternative material would require around 7 to
9% or more of weight gain on the tablet.
Many drug products would not end up with the
same properties they have currently. You might
be okay with certain immediate-release products,
but when you start to get into modified-release
products, the level of the coating is critical to the
release of the drug. Right now, there really are no
alternatives that work well in any sort of modi-
fied-release application. It’s not even possible to
reformulate those products at this point.
Some pharmaceutical industry associations
estimate that it would take between half a million
and 1.5 million euros to reformulate a product
because it is not only the technical reformulation,
but also stability studies, validation studies, as
well as regulatory post-approval change notifica-
tion and submission, which takes a lot of regula-
tory resources as well.
Industry experts have estimated that to try to
reformulate all these products in Europe, it would
cost 30 to 35 billion euros, if it was even physically
possible. That cost will obviously get passed on to
the consumer with increased drug prices. It will
also impact manufacturing because, if you have
to apply 2 or 3 times as much coating as you did
before, your plant’s manufacturing capacity has
just been lowered by 2 or 3 times. Chances are,
you won’t be able to make nearly as much prod-
uct with the equipment you have, which would
impact plant capacity significantly.
But the impact I want to stress is the patient
impact due to drug shortages and availability
of medicines in Europe. Many companies have
already said that they have no intention of refor-
mulating products just for Europe unless there’s
an economic model that makes it worthwhile. For
many older drugs, lower-volume drugs, special
populations, pediatric drugs, and orphan drugs,
there is no economic justification to reformulate,
especially when TiO2 is still okay in almost all the
rest of the world. Many companies would simply
withdraw drugs from Europe, and those European
patients would no longer have many of the drugs
that they need for their health.
With foods, you don’t have some of the same
light stability issues because shelf life is usually
weeks or months instead of years like you have in
pharma. Also, food companies reformulate prod-
ucts all the time. There’s no regulatory approval
process or stability and validation studies, etc.
Plus, they may have the ability to use other things
that don’t have precedence of use in the pharma-
ceutical industry.
It’s not that it’s not a big deal for foods. It was a
real struggle and a lot of cost for food companies
to reformulate where they have. That’s why many
food companies didn’t reformulate some of their
products and just sell them outside of Europe.
Dietary supplements are kind of in the middle.
It’s more flexible to make formulation changes,
because you don’t have the same kind of regulatory
approval process as you do with drugs. But many of
the technical challenges are very similar to what is
seen with drugs, because dietary supplements are
also tablets and capsules. That’s why the food ban
in Europe has created significant challenges for
dietary supplement companies, and some no lon-
ger sell certain products in Europe.
Q:
The EU ban has prompted other regulatory agen-
cies to reevaluate TiO2 and issue statements
about its safety. Which agencies have done so, and
what have they concluded following that process?
A: Health Canada did a very detailed assessment
of TiO2 safety after the EU ban. They looked
at everything that EFSA looked at and additional
data that they requested, which EFSA didn’t do,
and Health Canada totally disagreed with the con-
cerns the EFSA Opinion brought up. They didn’t
see any significant safety concerns and published
a report on their website that says they have no
intention of taking any sort of regulatory action on
TiO2 in Canada based on this data.
In Australia and New Zealand, FSANZ, their
regulatory agency on the food side, did a similar
evaluation and published a report on their web-
site that came to the same conclusion. They dis-
agreed with the EFSA Opinion. They looked at all
the data. They didn’t see any a concern and have
no intention of taking any action.
In the UK, which is no longer part of Europe, they
have their own regulatory agency, the FSA, that does
their food evaluations. They looked at this Opinion
and also came to a different conclusion and pub-
lished an interim report on their website that said
they disagreed with the EFSA Opinion. They saw no
safety concerns and, in fact, were extremely critical
of the EFSA Opinion, saying that EFSA was unneces-
sarily scaring consumers without justification.
In the US, the FDA looked at everything EFSA
looked at as well as a lot of additional data they
requested, and though they haven’t published an
official report like we saw in Canada and New
Zealand, they did an interview for a food maga-
zine (Food Navigator) that basically said they
disagreed with the EFSA Opinion and didn’t see
any problem as long as you meet the current cri-
teria for TiO2, which is a 1% limit. The Titanium
Dioxide Manufacturers Association (TDMA)
then asked them if they would provide a specific
statement on this, and the FDA gave TDMA a
statement they could publish on their website
that basically says that the FDA doesn’t have a
concern with TiO2 safety.
Interestingly, last year, some consumer groups
filed a color additive petition with the FDA to
try to get TiO2 banned. The FDA has not come
out with their formal position on that petition
yet, but on March 4th, 2024, they published a
new page on the FDA website called “Titanium
Dioxide as a Color Additive in Foods” in which
they state that FDA doesn’t have any concerns
about the safety of TiO2.
Finally, the ban in Europe triggered the Joint
Expert Committee on Food Additives ( JECFA) —
the WHO/FAO group of world-class toxicologists
that do the safety evaluations for food additives
that most countries use as a basis for their assess-
ments — to do their own reevaluation. Late last
year, JECFA published their Opinion and not only
said that they don’t see any concern about TiO2
safety and don’t agree with the EFSA Opinion, but
that they were going to reconfirm their ADI for
TiO2 of “not specified.” For JECFA, an ADI of not
specified is the highest level of safety. That means
they feel it’s so safe, there’s no reason to have an
upper maximum on the use level other than to say,
use it at good manufacturing practice.
The JECFA Opinion should be the basis for how
most countries around the world look at TiO2
safety. In fact, many countries had said they weren’t
going to come out with their own opinions until
they saw what JECFA had to say.
A few countries, primarily in the Middle East,
tend to follow what Europe does, because they
don’t have their own experts in house to do these
types of evaluations. A few Middle Eastern coun-
tries did say they were going to go forward with
the ban, but we’ve even heard inklings behind the
scenes that some of them, seeing what JECFA had
to say, may reconsider.
Q: Late last year, California passed the California
Food Safety Act, which bans the additives,
brominated vegetable oil, potassium bromate, pro-
pylparaben, and red dye #3. An early draft of that
bill also included TiO2, but it was removed prior
to passage. This is the first time a US state has
banned food additives that are currently permit-
ted by the FDA, and other states, including Illinois
and New York, have been considering similar legis-
lation. What will be the consequences if US states
begin to ban TiO2 on a state-by-state basis, even
while the FDA continues to assert that it is safe?
A: There is absolutely no rationale for why poli-
ticians should be making decisions on food
safety rather than the FDA, who has all the exper-
tise and is legally responsible for making those
decisions. And there was no additional scientific
explanation justifying why this material should be
banned in California, other than Europe did it.
I’ve already told you all the problems with the
European decision, and there are problems with
European decisions on some other materials on
this California list as well, where there’s not much
justification for real safety concerns. There are a
couple additives where there are some question
marks, and FDA has been taking some action on
these already. Maybe some would like it faster, but
FDA wants to make sure they look at all the data
before they make a call.
But to your point about the implications of
states taking this on, it could be disastrous if we
start to see a patchwork of regulation. I don’t know
how trade can possibly deal with different require-
ments on what ingredients are okay or not from
state to state.
Many folks in the industry stood up for TiO2 and
said there was nothing to justify banning it. And it
did get removed from this legislation. But the fact
that this bill went through on these other materi-
als is still a big deal, because this is the first time
that a state has challenged the FDA’s authority to
make food additive safety decisions, and where
that could go is, frankly, really scary. You would
have politicians making decisions about food
safety. Frankly, they don’t know what they’re talk-
ing about when it comes to toxicology and safety
APRIL 2024 | www.processingmagazine.com 25
 "What happens if a state decides they don't like an FDA-
approved drug for diabetes, so they're going to ban it?"
profiles, they just take what they hear in the media
and from consumer activist groups.
If we have these groups or the states taking
these kinds of actions, nobody knows where this
could go. You could start to see particular states
want to ban additional materials beyond food
additives. What happens if a state decides they
don’t like an FDA-approved drug for diabetes, so
they’re going to ban it? How does the country deal
with that? How does the industry deal with that?
The FDA has been given federal authority to make
these decisions; states should respect that. If they
want to argue in Congress that FDA needs more
funding or should do something differently, that’s
fine. But that’s the process for doing it, not saying,
“We don’t care what the FDA says, we’re going to
make the decision anyway.”
Again, there are other states that are putting out
similar bills, and I know industry is going to con-
tinue to try to work with those states. But hopeful-
ly at some point maybe the FDA or somebody will
step in and do some sort of preemption to say that
this needs to be done at the federal level, because
that’s the only place where it makes sense.
Q: In a May 8, 2023, post on its website, the
Environmental Working Group said, “The
Food, Drug and Cosmetics Act does not require
the FDA to regularly reassess the risks of chemi-
cals it has approved for use in food. So, decades
may pass without agency reassessment of the
safety of chemicals like titanium dioxide.” Setting
aside the safety or potential risk of titanium diox-
ide, are there gaps in the current federal law that
may allow additives and chemicals once consid-
ered safe to remain on the market too long after
health risks have been identified?
A: I know this question comes up, and I think
what they’re saying is there’s nothing that says
the FDA has to re-review a food additive every 5
years or whatever it might be. That’s true. The law
does not require the FDA to reassess a food addi-
tive after X number of years. But should it? That’s
an awful lot of resources to go to reassessing well-
known, commonly used food additives over and
over again, unless you have a reason to think there
might be an issue. And again, when the FDA sees
any kind of evidence pop up in the literature or
start to come out of the media about concerns or
new study data that shows something different,
FDA does look into that. They don’t do it public-
ly, where they’re out there publishing all kinds of
26 Processing | APRIL 2024
stuff. They do those assessments to determine if
there is a need to do a further big reevaluation. In
some cases, there is; in some cases, there isn’t. Just
doing reevaluations for the sake of doing reevalu-
ations is a waste of time and taxpayer money,
unless there’s some reason to think a reevaluation
might be needed.
I actually had discussions with the FDA, where
they had some questions about TiO2 shortly after
the EU Opinion came out. They already had a com-
mittee that was doing the reassessment process.
So, the FDA was very active, but again, they don’t
go out and publish and say the FDA is doing a
reevaluation of this because, until they see some
evidence of concern, they don’t want to create
worry that there might be a problem.
Q: In your opinion, what can be done to improve
the process and boost consumer confidence
that additives and ingredients that have been
approved by the FDA are indeed safe for human
consumption?
A: A lot of discussions have been going on within
the agency over the last year or two, especially
where there’s a whole reorganization effort within
the FDA, because these questions have been out
there about whether or not they’re really on top of
this and following up on various things. And the
FDA has restructured how the food side of FDA
is going to work going forward and has come up
with new procedures that hopefully will help give
consumers more confidence that these ongoing
assessments are occurring. Because, again, in the
past they did occur, they were just done in a more
unstructured way, based on the evidence that was
coming in and then doing an internal assessment.
I think, under the new structure and procedures
they’re establishing, there will be a little bit more
formality to that and probably a little bit more
public information that comes out that may help
that perceptional issue. I don’t think there’s any
concern there, but I think they need to be able
to show consumers a little bit more about what
they do internally, so there can be that confidence
building that’s necessary.
(You can listen to this entire interview by going
to the “Podcasts” page on the Processing website or
searching for “Ear on Processing” wherever you get
your podcasts.)
Black Diamond Regulatory Consulting
www.blackdiamondregulatory.com
 CHEMICAL PROCESSING
DATA ESTATE MODERNIZATION HOLDS THE
KEY TO SMARTER AND MORE SUSTAINABLE
CHEMICAL
PROCESSING
Chemical processors must first modernize their
data estates before they can truly make headway
with their smart manufacturing plans.
By Vivek Sandell, Capgemini Americas
P
rocess manufacturers have spent years
and millions of dollars revamping fac-
tories and scaling smart plants. These
enterprises recognize that intelligent
solutions and connected operations —
from the factory floor to the back office
— will help reduce costs, improve efficiencies and
sharpen their competitive edge.
Chemical processors are no exception. Like
many process manufacturers, chemical processors
are also implementing digital capabilities, such as
IoT sensors, robotics and digital twins, to enable
smarter, safer and more sustainable processes.
However, the catalysts behind chemical proces-
sors’ transformation initiatives slightly vary from
others in the broader industrial manufacturing sec-
tor. Historically, energy-intensive processes, asset-
heavy operations and high costs of safety incidents
have driven the chemicals industry to adopt digi-
tal technologies. More recently, the industry is con-
tending with increased energy costs, supply chain
disruptions and worsening talent crunch with lim-
ited intake of new talent.
The resulting emphasis on digital transforma-
tion and smart manufacturing has exposed a com-
mon gap for chemical processors — effective use
of operational data. Many companies do not have
a strategic path to data estate modernization.
Digital transformation requires data estates with
23353649 © Ulrich Mueller | Dreamstime.com
April 2024 | www.processingmagazine.com 27
secure and efficient collection, selective storage
and cost-effective management of data in cloud or
hybrid environments. Thus, chemical processors
must first modernize their data estates before they
can truly make headway with their smart manufac-
turing plans.
Identifying barriers
To begin solving this issue, it is important to explore
the various interrelated challenges behind data
estate modernization for many chemicals enter-
prises. The most common underlying issue stems
from the heavy legacy burden in chemical process-
ing. Years of mergers and acquisition with limited
integration means operations are littered with vari-
ability in processes, equipment, instrumentation
and site IT infrastructure. This variability makes
uniform capture of operational insights difficult and
cost prohibitive. Organizations struggle to collect
relevant data from older machines, transport data
into cloud or hybrid environments, and weave the
data into homogeneous analytical insights.
Another complicating barrier for chemical pro-
cessors is the variety in operational sites in terms
of size, complexity, tenancy (owner/tenant),
geographical location and network connectivity.
This makes collection, management and utiliza-
tion of data for intelligent operations very difficult.
Cloud technologies sometimes help overcome this
barrier, but it is difficult to justify the required local-
ized investment without a consistent strategy.
Lastly, data science talent and skill gaps pose
considerable barriers. Executing smart manufac-
turing strategies involves modeling complex sys-
tems that are most effectively modeled as data
models instead of mathematical and physics-based
models. This requires data scientists who under-
stand not only state-of-the-art data science tech-
nologies, but also complex manufacturing equip-
ment as well as the system context in which they
"Digital transformation and increasing adoption of
smart manufacturing is now an established trend
in the chemicals industry."
operate and the institutional knowledge crucial for
extracting insights. Talent with such skillset combi-
nation is hard to find (and retain) and requires years
to cultivate internally.
Addressing challenges
Digital transformation and increasing adoption of
smart manufacturing is now an established trend
in the chemicals industry. With visibility and sup-
port all the way to board-of-directors level, the bar-
riers to investments in technology projects are
now lower than they have ever been. The environ-
ment is right to implement supporting IT improve-
ments, starting with a broad-based data estate
modernization.

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 "The good news is that data estate modernization,
and the digital transformation it enables, addresses
long-standing challenges for the chemicals industry."
There are many approaches chemical companies
may take based on their context, but there are a few
underlying tenets that can inform data estate mod-
ernization strategies to support digital transforma-
tion of chemical processing operations.
• User-centric and process-driven digital transfor-
mation: IT departments should be relentlessly
focused on consumers of data in their approach
to digital transformation. Use cases centered
around improving user experience in day-to-
day operations add the most value in a digital
solution. For example, connected worker use
cases that allow maintenance notifications and
updates to critical master data from the field not
only improve user experience, but also the quali-
ty of data available for operations. Similarly, data
models should be designed to span broad, end-
to-end processes to deliver the benefits of digital
transformation. For example, asset performance
improvement requires an ability for end-to-end
performance analytics that can be delivered with
2305PRO_AssuredAutomation.indd 1
integrated, centralized cloud data repositories.
• Holistic data architecture: When envisioning
the data estate architecture, companies should
account for how data travels throughout the
organization and minimize data stranded in dis-
connected assets. This consideration includes
internal systems for ERP, cybersecurity, engineer-
ing, plant operations, organizational knowledge
management and collaboration, etc. Roadmaps
for storage, computing and network infrastruc-
ture are also essential. External consideration
includes supply chain partners as well as tech-
nology providers and their roadmaps.
• Standardization: Process standardization is often
overlooked in data architecture. Data strategies
should be implemented in conjunction with the
adoption of industry standard processes. This
addresses the inherent barrier of variety across
legacy operations of chemical processors and
improves the ability for collaboration with indus-
try peers.
  
New!


   
   
 

   
  

    
     
   

An overarching success factor in data estate mod-
ernization is that it needed to be an organization-
wide imperative. To realize the inherent benefits
of business growth, reduction in operational and
product cost, increased operational performance
and sustainability, data should be not only the busi-
ness of IT departments, but of all operational units
and departments. This organization-wide data cen-
tricity requires consistent, value-centric messaging
from executive leadership.
The good news is that data estate modernization,
and the digital transformation it enables, addresses
long-standing challenges for the chemicals indus-
try. It helps to address the talent crunch by enhanc-
ing virtual collaboration with experts across a com-
pany, while also improving the industry’s image to
attract new talent. The nimble and agile operations
make possible sustainability initiatives that tend
to have smaller payoffs over longer time horizons.
However, to see the benefits, chemical processing
leaders must accelerate their data estate modern-
ization strategies.
Vivek Sandell is Principal & Chemicals Segment
Leader at Capgemini Americas.
Capgemini Americas
www.capgemini.com
  

/TSV
April 2024 | www.processingmagazine.com 29
3/29/23 1:49 PM
 PLANT MAINTENANCE & SAFETY

KEY IN LEAK DETECTION AND DOWNTIME REDUCTION H

ACOUSTIC IMAGING
Acoustic imaging can go a long way in quickly and cost
efficiently identifying and repairing leaks, saving companies
in downtime while making needed repairs.
idden leaks in equipment are the
nemeses of every manufacturing
plant operator. Beyond performance
issues and reduced energy efficiency,
the damage caused by unnoticed
gas or compressed air leaks can be
substantial, wreaking havoc on equipment, result-
ing in downtime and significant costs. To prevent
these issues, regular maintenance and the use of
acoustic imaging technology can be beneficial
in detecting, identifying and fixing these hidden
leaks, ultimately reducing costly downtime and
improving operational efficiency.

By Justin Sheard, Fluke How acoustic imaging works

Acoustic imaging can be a game changer in
detecting leaks. It offers a host of benefits in
that it provides versatile, quick and accurate
detection, is safe and non-invasive, and provides
operational continuity. Acoustic imaging uses an

30 Processing | APRIL 2024

  Acoustic imaging
technology can be used
to quickly detect and
pinpoint the location
of leaks in large areas,
overhead or in tight
spaces without having to
shut down production.
 The Fluke ii900 and
ii910 acoustic imagers
include technology
that makes it possible
to see sound for easier
detection of leaks with-
out specialized training.
All images
courtesy of Fluke
Benefits of acoustic imaging to detect leaks
Through the use of acoustic imaging to locate hid-
den leaks, manufacturing facilities can avoid some
of the more costly issues. The following are some
examples of issues that acoustic imaging helped
visualize to quickly repair:
• Control air pressure regulator failure.
A control air pressure regulator is intended to
keep internal components dry. Through use
of the acoustic imager, an operator was able
to visualize two leaks, which were caused by
bad seals.
• Process control valve condensation. In the
case of an unfounded electrical failure, it turned
out the root cause was not electrical. The acous-
tic imager identified a compressed air dryer that
was not operating efficiently, which caused con-
densation in the area and eventually caused the
electrical components to fail.
• Pressure regulator corrosion. A user had
a pressure regulator that kept failing, but
the root cause could not be determined.
acoustical array of tiny super-sensitive micro- An acoustic imager pinpointed small car-
phones that detect both sonic and ultrasonic bon dioxide leaks nearby which over time
sound waves. The acoustic imager recognizes can cause components to break, negatively
a sound source at a potential leak location and impacting uptime and/or quality.
then it applies proprietary algorithms that inter- • Air line leaks reduce performance. Leaks in
pret the sound as a leak. The results produce a pneumatic systems are a quality defect that
color map superimposed over the visible light can impact the performance of onboard sys-
image — showing exactly where the leak is. The tems. Acoustic imaging can find these leaks
results are displayed on a screen as a still image more quickly than conventional methods of
or a real-time video. leak detection, which can easily miss these
Large areas can be scanned quickly which helps types of leaks.
locate leaks much faster than other methods. It • Product reservoir leaks. Acoustic imaging
also allows for filtering on intensity and frequen- can identify leaks such as these, which can
cy ranges. One example of an acoustic imager impact batch integrity, such as contamination
in action: a team at a large manufacturing plant of the product due to infiltration of environ-
recently used two units to locate 80 compressed air mental particulates.
leaks in one day. The maintenance manager said it • Dust collection system leaks lead to inef-
would have taken them weeks to find that number ficient performance. Acoustic imaging can
of leaks using traditional methods. By finding and identify leaks in dust collection systems,
fixing leaks quickly, the crew also saved potential which can cause inefficient operation and
downtime, which at this plant can cost an estimat- could lead to added maintenance or reduced
ed $100,000 an hour in lost productivity. performance or blocks.
• Control air regulator not venting properly.
When a gasket between the two mounting
surfaces failed, acoustic imaging helped prove
the device was not venting excess pressure,
but simply leaking.
• Robotics leaks that impact product quality.
Oftentimes when suction issues are reported, all
components are replaced because it is difficult
to isolate the problem. However, using acous-
tic imaging can allow operators to check each
cup independently to check for leaks instead of
replacing all the components.
• Steam system leaks are expensive. Steam sys-
tems are often inaccessible, making it difficult
to identify issues. Air or gas leaks can be difficult
to identify, especially if you do not know where
to look. The use of acoustic imaging can easily
identify these and other types of air or gas leaks
to keep systems up and running efficiently.
Acoustic imaging can go a long way in quick-
ly and cost-efficiently identifying and repairing
leaks, saving companies in downtime while mak-
ing needed repairs. Choosing the right acoustic
imaging technology can significantly impact leak
detection and functional efficiency. When select-
ing an acoustic imager, look for the right acoustic
imager based on your environment and specific
needs. And be sure to consider these core acoustic
imaging attributes: frequency range (in hertz), dis-
tance (in feet or meters), minimum frame rate and
reporting functionality.
Justin Sheard is a senior engineer and application specialist with the
Fluke Industrial Imaging group. He has more than 20 years of experience
designing handheld electronic products. While holding leadership roles
in the development of Fluke thermal imagers, Sheard accumulated more
than 10 patents. In his current position as application specialist, Sheard
works directly with customers offering training and application support
while learning about their workflows and daily challenges.
Fluke
www.fluke.com
APRIL 2024 | www.processingmagazine.com 31
 OPERATIONS

T
urning a plant around is not an effort
undertaken lightly. It is complex and
frequently includes working with hun-
dreds of technicians from multiple ven-
dors. Coordinating those vendors to pro-
vide plant maintenance, restructuring
and renewal tasks can feel overwhelming, whether
they are focusing on one particular system or the

BEST PRACTICES TO MAKE

whole plant.
Additionally, most plant turnarounds require tak-
ing some plant processes offline, which stops pro-

PLANT TURNAROUNDS
duction and idles employees. Keeping turnarounds
efficient also means lowering overall contractor
costs because personnel will not be on-site for as
long. For larger plants, it can take years of planning

MORE EFFECTIVE AND

to ensure a turnaround goes smoothly, with turn-
around-related activities often representing most of
a facility’s annual maintenance budget. It is impor-
tant not to mismanage the process and incur avoid-

EFFICIENT
able expenses.
Fortunately, there are seven best practices to help
ensure a plant turnaround is managed efficiently
and effectively.

1. Engage early with trusted suppliers

Proper planning with trusted partners can make
turnaround efforts go more smoothly.
By Mike Aughenbaugh, Swagelok Company
Avoiding potential pitfalls requires extensive plan-
ning that can often take years, prior to implement-
ing a turnaround project. In the planning process,
engaging early and often with trusted service pro-
viders can make the difference between a success-
ful and unsuccessful venture.

32 Processing | April 2024

 Figure 1: Do not wait until your turnaround is underway to engage with
your most trusted component suppliers. Connecting early on will help
streamline the entire process.
All images courtesy of Swagelok Company

The complexity of a facility’s major fluid systems

often goes unnoticed if they are working proper-
ly. However, during a plant turnaround that com-
plexity comes to the forefront. Fluid systems often
require specialized parts and components built
with specific alloys, which allow them to stand up
to the rigors of particular applications. Procuring
specialized components often means taking longer
lead times into account, but by discussing needs
with a supplier early enough in the process, unique
component requests can be incorporated into the
overall project timeline.

2. Identify areas of new opportunity

Beyond lead times, engaging early with trusted ven-
dors also allows for modifications to systems that
can help them operate more reliably. Strategic part-
ners can often see inefficiencies in systems that
plants may not be aware of.
Improvements do not occur without significant
advanced planning. When a decision is made
to change systems, those choices often require
advance approval before the turnaround starts
due to management of change (MOC) require-
ments. Additionally, engineers may institute a
freeze after which changes cannot be made, so
making sure these decisions are made well in
advance is crucial.
One potential area that could enhance a sys-
tem is choosing preengineered and preassembled
grab sampling panels. By replacing traditional site-
constructed grab sampling systems, an assembled
 Figure 2: Opting for prefabricated grab sampling panels is one way to account for potential knowledge
deficits among different suppliers to ensure consistent quality installations during turnarounds.
panel reduces the chance for user errors when For example, it may be impossible to know the
samples are pulled without fundamentally alter- exact number of parts and components neces-
ing the system design. Additionally, operators may sary to complete a full plant turnaround because
decide to take the opportunity to upgrade valves of the complexity of most industrial fluid systems.
to low-E versions instead of merely replacing cur- To account for this variability, teams should discuss
rent components with potentially outdated valve how to stock a variety of hoses, valves and adapt-
designs. Turnarounds are a great time to make ers with suppliers so they will be ready for use at a
these improvements. moment’s notice. This discussion should occur long
before the project starts. Stockpiling common com-
3. Prepare for the unexpected ponents can save significant time and money, rath-
No plant turnaround will occur without some er than waiting to order components in the middle
unforeseen circumstances cropping up. Exploring of the installation and experiencing delays.
these possible variables and contingencies and That said, it does not make financial sense to stock
planning for them is another essential way to so many components that it leads to unused inven-
improve overall project efficiency. tory when the project is done. Reputable suppliers

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will allow temporary stock or consignment inven-
tory, so the parts are always only a phone call away.
Under this system, plants only pay for the parts they
use. Such agreements can also mitigate supply chain
issues associated with natural disasters, pandemics
and other events beyond the operator’s control.

4. Ensure the availability of local support

Choose vendors to partner with that can offer local-
ized support close to the plant so they can source
unanticipated part needs quickly and efficiently.
Reliable vendors should also be available to come
on-site to help install systems correctly.

5. Keep an eye on the installation

of critical parts
On projects as large as the average plant turn-
around, there may be hundreds of different techni-
cians working at a facility at any given time. They
will come from different firms and disciplines and
may even come from other countries.
Managing a diverse workforce can be challeng-
ing because the levels of installation knowledge
may differ significantly from vendor to vendor. It
 Figure 3: Reputable suppliers can put owners’ minds at ease by anticipating supply needs, as well as offering to stock temporary or consignment inventory.
also creates the possibility of inconsistencies in
installation practices, which cannot take place on
a turnaround project. Experienced technicians will systems improves the life span of most mechanical cannot default to less expensive and lower-qual-
have insights into particular plant functions that seals. Analytical subsystems, including fast loops, ity components. Once vendors introduce incon-
other less-experienced technicians may not. They field stations, calibration and switching modules, sistent quality into an industrial fluid system,
will understand the optimal way to route tubes sample probes and fluid distribution headers, can poor performance typically follows. Poor qual-
to eliminate vibration damage over time. They also bring efficiency and consistency to operations ity components can fail prematurely and drive
will also know which tools are necessary to do an with simplified design footprints. higher, unnecessary maintenance costs. Stay up
installation properly, preventing unnecessary dam- to date on the standards for fluid system design
age to components that might affect performance 7. Maintain tight quality control and specify the project accordingly. Do not allow
down the road. Finally, controlling the quality of the parts and contractors to intermix and interchange parts
The goal, then, is to ensure the technicians work- components can mean the difference between between suppliers, which can not only negative-
ing on the turnaround are as experienced as possi- a successful turnaround and an unsuccess- ly affect performance but can also complicate
ble. Incorporating specific training and certification ful one. Specify with precision so contractors maintenance down the road.
requirements — such as the JIP 33/IOGP specifi-
cations that require certified training by the man-
ufacturer — into the solicitation process ensures
standards are met across the board. It will help
eliminate the inexperienced technicians and ven-
dors who might slow down progress on the turn-
around and provide some security in the fact that
the job will be done in accordance with industry
best practices. It also ensures technicians are well
trained before the work begins.

6. Seek out prefabricated assemblies

Another method to help reduce installation errors
from occurring is to specify as many prefabricat-
ed, preassembled and pretested systems as possible
before the turnaround. Contractors will have fewer
moving parts to install and test, which can stream-
line installation and make it easier for technicians.
Using prefabricated assemblies also allows for
potential expertise and knowledge deficiencies
between different vendors and contractors, while
saving money on labor at the same time. As dis-
cussed earlier, installing grab sampling panels is
one area where prefabricated components are com-
mon. Additionally, using mechanical seal support  Figure 4: The most effective component suppliers should offer localized support, which can make it easier to receive system-critical parts in a timely manner.

34 Processing | April 2024

  Figure 5: Standardized
mechanical seal support
systems are easier to
install and maintain,
while also lasting longer.

 Figure 6: Prefabricated
fast-loop systems allow
even inexperienced
technicians to install them
with consistency and
precision, keeping plant
turnarounds on schedule

Why this matters
Following these seven practices from the plan-
ning to the execution of a plant turnaround will
smooth out the process. The turnaround will be
more efficient and effective and lead to better per-
formance and reliability of fluid systems over time.
Component suppliers should be able to serve as a Mike Aughenbaugh is an associate target
guide through the process to make sure the next market manager for Swagelok Company.
turnaround will be as successful as possible.
Swagelok Company
An original version of this article appeared on the www.swagelok.com
Swagelok Reference Point blog.

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April 2024 | www.processingmagazine.com 35

 SOFTWARE
DIGITAL TOOLS
REDUCE PROJECT
EXECUTION TIME
New software tools create instrumentation
lists automatically from P&IDs, eliminating errors
and increasing personnel productivity.
By Ryusuke Yokoyama and Yuichi Ishida, Yokogawa Electric Corporation
F
or all of the advances in industrial auto-
mation technology over recent decades,
launching a major unit or plant upgrade,
or building an entirely new plant, can be
a very challenging proposition for many
companies. While actual statistics are
scarce, many projects invariably go over budget
and take more time to complete than expected.
The result is increased project costs, made worse
by delayed startup that creates a cashflow gap as
expected income is pushed out into the future.
Many software tools have been created to help
with all manner of plant design and project man-
agement/scheduling, and these often help, but
incompatibilities of processes and methods often
36 Processing | April 2024
create gaps in the timelines. Bridging those gaps
requires many manual operations to connect all the
divisions of a company and its partners into a com-
prehensive plan, and these manual hand-offs are
frequently the source of problems. Delays caused
by data incompatibilities and other manual rework
leave actions unfinished, plus materials missing or
mis-specified.
Fortunately, a solution for these and related
issues is now available, as described next.
Issues with instrumentation lists
A prime source of problems is creating instru-
mentation lists from piping and instrument dia-
grams (P&IDs). Accurate instrumentation lists are
needed because these documents are used to speci-
fy and purchase instruments, and for other purpos-
es, including:
• Determining networking requirements for con-
trol systems, to which instruments are typically
connected.
• Designing the mounting details for each
instrument.
• Designing the portions of the piping systems
to which instruments are connected and/or
inserted.
• Making sure flow elements inserted into pip-
ing systems have adequate downstream and
upstream piping runs.
• Making provisions for the installation of
impulse lines for certain types of pressure
instruments.
• Designing thermowells for the thermocou-
ples and RTDs associated with temperature
instruments.
• Ensuring all vessels have provisions for install-
ing the process penetrations required by most
level instruments.
• And many other design details.
Even if P&IDs from which instrumentation lists are
flawlessly accurate, engineers responsible for creat-
ing designs based on specifications they show must
extract sufficient information to create detailed and
accurate instrumentation lists. To compound this
problem, engineers skilled in this type of work are
in short supply at many companies.
Getting from 2D CAD drawings to flawless instru-
mentation lists, with potentially thousands of indi-
vidual line items, is fraught with opportunities for
mistakes and omissions. To make matters worse,
if there are alterations to the P&IDs affecting
 255670159 | Power © Forkosmos | Dreamstime.com
instrumentation lists, changes must pass back-and-
forth, requiring extensive manual handling.
Addressing the issues
To address this and other issues, Yokogawa is at the
forefront of the transition from Industrial Automation
to Industrial Autonomy (IA2IA), which in this case
can be used to improve process plant design activi-
ties through the use of digital technologies.
To solve this problem Yokogawa provides OpreX
Data Model Broker with its Design Diagram
Converter data conversion tool. OpreX Data Model
Broker is a data transformation platform that makes
 Figure 1: Even when project-specific symbols are used, designers and
engineers can create standard symbols based on them and then improve
recognition accuracy by adjusting them. Once built, the same settings can
be used to process large numbers of P&IDs.
Courtesy of Yokogawa
use of the ontology artificial intelligence (AI) tech-
nique to convert and verify data that is scattered
across various systems. Ontology is an AI mech-
anism for defining the meaning of information,
allowing computers to mimic how humans under-
stand and make associations within complex data.
Design Diagram Converter is a data conversion
tool able to read P&IDs created with 2D CAD soft-
ware, and then automatically generate P&IDs and
various documents — including instrumentation
lists, piping line lists and piping material takeoffs —
each of which can be processed by computers.
In this context, the data conversion tool can
read P&IDs created with various 2D CAD soft-
ware tools using normal design techniques. It can
then convert them to a common industry format,
ISO 15926, to overcome any format incompatibili-
ties. More importantly, it automatically generates
 Figure 2: Using Yokogawa’s Design
Diagram Converter shortens
instrumentation list creation by more than
half. Once image pattern consistency is
established, the time can be even faster.
Courtesy of Yokogawa
computer-processable P&ID data, along with the
documents listed earlier. With this capability to
automate plant engineering work that previous-
ly had to be done by hand, manual tasks are mini-
mized through digital conversion technology in a
very critical area.
Software solutions
P&IDs play an essential role not only in design
and construction, but also in the operation, main-
tenance and modification of all types of process
plants, including chemicals, life sciences, oil and
gas, and others. Process engineers create P&IDs to
help personnel tasked with implementing and oper-
ating plant instrument, piping and machinery, but
these diagrams are intended primarily for viewing
on paper or a computer screen.
They are rarely optimized for computer processing,
which is necessary for frequent information exchang-
es when P&IDs make the transition to subsequent
engineering departments. In such cases, it is neces-
sary to have a team of specialists manually extract
and process the data, introducing many opportuni-
ties for errors, omissions and other quality issues.
To address this issue, all the P&ID CAD files are
imported into the data conversion tool. With high
accuracy, this software reads P&IDs created with
all common conventional 2D CAD software tools.
The tool then creates data using the pattern analy-
sis of symbols on P&IDs, and using this data, it can
export P&IDs in an ISO15926 compliant XML for-
mat, and it can create various lists.
Conditions are defined for shapes to be detect-
ed and the parts that make up the shapes, as well
as settings for the connection relationships with
other detected shapes, and so forth. In situations
where interpretation of information on a P&ID is
April 2024 | www.processingmagazine.com 37
 "It is important to distinguish between adjustments to pattern
settings, which is a relatively simple process, and AI."
necessary, the software will present the choices to
human operators, instead of leaving the decision to
an algorithm. For example, users can freely adjust
pattern settings (Figure 1), and then generate a list
with high extraction accuracy.
It is important to distinguish between adjust-
ments to pattern settings, which is a relatively sim-
ple process, and AI. Although AI operates behind
the scenes, plant personnel working with the data
conversion tool do not need AI tuning or other
expertise, and it is much easier to adjust pattern
settings than it is to perform AI tuning. High accu-
racy conversion is the result because users can cus-
tomize pattern setting in detail.
This creates an instrumentation list up to 60%
faster than with traditional manual methods
(Figure 2). Once edited patterns are created, they
can be retained and used again or adjusted as need-
ed based on the results of checking.
The result is an instrumentation list created in
less than half the time of manual methods, even
including checking. By automating a task that pre-
viously had to be done manually, the workload is
significantly decreased, while quality is assured
through reduction of human error by using digi-
talized engineering work processes.
Digital transformation at all levels
The digital tools described in this article are being
used by process manufacturers and their staff as
they continue on their digital transformation jour-
neys. As with all such tools, automating manual
tasks to eliminate errors, increase productivity and
speed project completion is a critical component.
These and other steps on the digital transformation
journey will help process manufacturers stay com-
petitive, while attracting a workforce eager to use
the most advanced software tools.
Ryusuke Yokoyama is a sales promotion
manager for OpreX Data Model Broker with
Yokogawa Electric Corporation. Since join-
ing Yokogawa in 2000, he has been
involved in sales and project execution for
integrated control systems. Yokoyama uses his experi-
ence to lead product planning and development, com-
bining customer requirements with the latest technolo-
gy available to achieve optimal results.
Yuichi Ishida is responsible for sales pro-
motion of system products with Yokogawa
Electric Corporation. He was a web engi-
neer before coming to Yokogawa in 2020,
where he made a career change to sales
promotion, especially through content marketing. Ishida
is mainly engaged in the preparation of brochures,
eBooks, press releases, and promotional videos for sys-
tem products, including Design Diagram Converter.
Yokogawa Electric Corporation
www.yokogawa.com/us

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38 Processing | April 2024

 ADVERTISER INDEX

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Assured Automation .......................................................................29 Eriez Magnetics .................................................................................... 3 Tecweigh................................................................................................35

B & P Littleford LLC............................................................................38 Hapman ...................................................................................................15 Thermal Care ........................................................................................14

Benko Products Inc .........................................................................28 MOTION ........................................................................................................5 Tri-Mer Corporation ..........................................................................38

Carrier Vibrating Equipment, Inc .......................................19, 21 Plast-O-Matic Valves Inc. ............................................................ BC Vanton Pump & Equipment Corp ..............................................11

Check-All Valve ..................................................................................... 7 Ross Mixers .........................................................................................IFC Vibra Screw Inc ......................................................................................1

Coperion Corporation .....................................................................33 Shelco Filters Inc. .............................................................................35 Xchanger Inc........................................................................................28

Dynamic Air Inc .....................................................................................9 Specialty Equipment .......................................................24, 25, 26

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APRIL 2024 | www.processingmagazine.com 39

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 Ear on

NEW PODCAST! LISTEN AND SUBSCRIBE NOW.

Greetings, and welcome to “Ear on Processing,” a series of podcast episodes by Processing and
Endeavor Business Media — hosted by Processing’s editorial staff. Ear on Processing is a weekly
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matter experts involved in process manufacturing. In Processing segments take a closer look at the
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