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Swagelok® Products Save Miles…of Paper
The Problem: A leading manufacturer of specialty/coated paper was experiencing losses due to the failure of a dye control panel. The losses occurred during a process that coats the paper with a thin film of blended dyes as it rolls off the headers. When a single air bubble is introduced into the “curtain,” it ruins the entire batch – and more than 1 mile (1.6km) of paper is wasted!
The inherent design of valves in the dye control panel lets pockets of air and old dye collect behind the ball. Because of the size of the valves, a number of dead legs were created within the panel, trapping air after the cleaning cycle and allowing it to emerge later during the production run in the “curtain”. In all, the manufacturer was faced with three problems: long, costly, and ineffective cleaning processes; increased downtime; and contaminated production runs.
The Swagelok Solution: Local Swagelok sales and service representatives quickly identified the source of the problem and demonstrated the benefits of replacing the existing ball valves in the dye control panel with Swagelok® DR series radial diaphragm valves and TS-style clamp fittings. The DR valve cluster, coupled with the TS flange products, reduced the footprint compared with the existing system.
The Benefit: The Swagelok DR and TS series designs improved process control and made maintenance easier. The manufacturer realized immediate cost savings by preventing dye waste during switchover to the cleaning cycle.
The dye “curtains” that are now produced to coat the paper no longer contain the intermittent air bubbles, resulting in increased production yield. Dye dispersal is even throughout the entire run, and the manufacturer has not experienced a failure since the switch to Swagelok products. Using this combination of products has saved the customer significant costs by preventing miles of wasted specialty paper. |
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