The world is becoming more volatile, uncertain, complex and ambiguous (VUCA) and the price of resources is rising. Plus, the responsibility is increasingly being placed on the manufacturer to consider ways to reduce their environmental footprint – consumers are increasingly looking for the most efficiently produced products. All of these factors mean that having full control of your processes is becoming of increasing importance.
Successful manufacturing does not come without its challenges. Amongst them is how to improve industrial processes. An ongoing battle that never ceases to unfold, process improvement is perhaps more relevant today than even before, especially in larger, more complex industries like chemicals, plastics, ingredients and food production. It is a means by which businesses can meet modern demands for quality, give themselves the edge in a competitive marketplace and weather the storm of unpredictable economics.
Why improving industrial processes is becoming more important every day
What do we mean when we use the term ‘process improvement’? For the purpose of the discussion here, the term is presented as a definition of the analysis and betterment of operations towards optimal efficiency and production. In short: ‘Creating the highest return with a minimal use of resources.’ These resources can mean basic ingredients, energy, labor, assets (like machinery), capital or even time.
Process improvement is an effective stimulant to quality, operational efficiency and, ultimately, profitability. There are many advantages to be had, included amongst which are less defects, faster production and reduced downtime.
How to start process improvements for your industrial site
But where to begin? Processes themselves, depending on the operation, are liable to be many and varied. The approaches to improvement are no less diverse. The briefest of internet searches will reveal a lengthy list of means that promise to make work life easier and profits higher – lean, 5s, Kaizen, Six Sigma. All offering numerous advantages, but at the same time, presenting a potentially confusing array of solutions suggesting a need for specialist support.
The benefits you can expect from improved dust & fume extraction
One area where process improvement can rapidly yield benefits, including a considerable return on investment, is dust and vapor extraction. The impact of effective emission control solutions is often underestimated.
There are diverse reasons to consider the optimization of industrial air extraction:
- Provision of a healthy workplace
- Operator safety and ATEX compliance
- Corporate social responsibility
- Compliance with emissions regulations
- Improved economic performance
- Energy reduction and recovery
Acting as a barrier, however, is a widespread lack of awareness. Often, there is a lack of knowledge within the site’s engineering department and a lack of perceived importance compared to other points of improvement. It’s unfortunate that this way, many benefits are overlooked.
For example, over-extraction may lead to clean workplaces. But extracting valuable product from the process into the filter may lead to massive unseen costs over the years. This makes a case for tailor-made and balanced extraction systems. By knowing how to address the situation, and with a little help, you can quickly reap considerable rewards.
How Pneumatic Conveying leads to better Industrial Process Performance
Optimizing Pneumatic Conveying of bulk solids, like powders and granulates by using compressed air of gas is key to process performance. When done correctly, less extraction and energy is needed preventing wasting resources. By truly understanding your products particles characteristics and by using modeling software, we are able to optimize your Pneumatic Conveying System leading to:
- Energy Efficiency
- Less product breakdown
- Yield Improvement
- Less product extracted from your process
- Prevention of Cross-contamination
- Easy Maintenance and Operator Friendly
- Low product wear
Pneumatic Conveying Systems can be differentiated in pressure and vacuum modes or a combination of both.
A proven process designed with your needs in mind: Continuous improvement in manufacturing
JOA has developed a process – tried and tested in the field – that can help you fully understand your process in order to provide you with a solution custom designed for your needs.
In addition to taking measurements, undertaking pre-engineering studies and site surveys, development, installation and aftercare of our own patented equipment, we are also integrators of proven equipment from diverse OEMs. As such, our solutions consist of multiple pieces of equipment, forming a holistic system, perfectly attuned to its role to create the best solution for your site’s requirements.
Pre-engineering Study – Find the best extraction solutions
With every business case being different, thorough analysis is required. JOA’s approach is to work together with your team of process owners, production specialists and operators to gather as much information as possible. This often includes measurements and operator interviews during a Site Survey. With this, we are able to develop the full understanding we require to provide the best solution, unique to your site.
Some manufacturers don’t know what to improve first. It can be hard to make decisions if you don’t know all the possibilities. That’s why you can also ask for a Masterplan. Here we identify and prioritize all upgrade in a clear report containing a decision-making matrix. This helps decision making based on compliance, costs, lead time and overall priority.
As Gas prices are on the rise, we encounter more and more requests with regards to Energy Reduction and Energy Recovery solutions. To get a clear overview of possibilities, we have developed a Quick Energy Scan. Similar to a Pre-Engineering Study, we investigate the site and see where we see opportunities to link waste energy sources with potential consumers. This can also be done for Low Grade Waste Heat sources. See also our blog on Industrial Waste Heat Recovery.
Air Technical Modeling – Stop guessing, start making decisions based on hard data
We combine 3D engineering with integrated Air Technical Modeling to guarantee efficient project execution for both greenfield projects and upgrades in running plants. Precisely identifying bottlenecks and predicting future performance, we can prevent unpleasant surprises and avoid costly learning on the job.
Air Technical Modeling is at the core of every solution provided by JOA. It distinguishes us from sub-optimal standard extraction solutions. Knowing for sure how and where to improve is often combined with Force Balancing to truly understand particles and Computational Fluid Dynamics (CFD).
Design & Engineering of Systems
With solutions engineered to your requirements, the long-term reliability of your system is assured. By finding balance in your air flows, the energy usage and unpredicted downtime is often reduced tremendously. Furthermore, we provide you with all the advice and service you need to undertake preventive maintenance and to handle any subsequent process and upgrade changes when requested.
Having developed over 2000 systems, worldwide and having an open mind to every new projects, enables you to further optimize your site’s performance. With every design, we combine hard data with you knowledge and expertise.
Realization & Implementation – Installation of Process Technology
Once you have approved our proposal, we can implement the system. All of our projects are carried out by dedicated project managers with multi-disciplinary backgrounds. Their experience ensures you of expert implementation of your system – on time and effective handling of any unpredicted setbacks.
Service & Spare Parts
Our commitment to you does not end with project completion. We stay in touch in order to provide you with the best possible service. Our service offering includes spare parts provision and tailored preventive maintenance to ensure the long-term reliability of your system and your process performance.
A portfolio of solutions to support the improvement of your processes
JOA has developed a broad portfolio of solutions aimed at supporting process improvement via dust, vapor, and fumes collection and extraction:
- Consultancy study – a first step to sound decisions based on measurement and air technical modeling.
- Dust collection & vapor and fumes extraction solutions – tailored extraction built on a proven track record for healthy, safe working.
- Energy recovery solutions – reducing negative environmental impact and optimizing process efficiency via industrial waste heat recovery.
- Central vacuum cleaning systems – Learn more about the benefits of an industrial CVC System
- ’Ultra-fine particle removal – offering optimal uptime, a healthy working environment and efficiency in operations.
- Acoustic cleaning in place – using acoustics to maintain flow in pipes, filters and silos in order to keep processes in motion.
- Automated air flow stabilization – giving you balanced extraction on demand, preventing wasting energy.
- Masterplan – tailored advice for future upgrade planning and ROI maximization.
- Balancing restrictors – preventing fouling, extending cleaning intervals and ensuring the optimal flow profile.
- Industrial conveying control unit – providing you with control of your processes for yield improvement of up to 2%.
- Scrubber technology – emissions control to keep you clean and compliant.
- Air Flow Measurement Unit – Measuring Flows & Volumes accurately to increase explosion safety, uptime and preventing pipe pollutions
To find out more about any or all of the above, get in touch. We’re looking forward to hear from you.
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