Industrial expertise

Quality of PDI on an industrial site

Requirements

  • Determination of the cause of durability problems
  • Establishment of recommendations to improve pellet quality

 

Service

Pre-test

  • Demonstration of the type of problem encountered
  • Definition of the objective of the study
  • Collection of information on the feed produced and on production lines
  • Collection of information on pelleting parameters
  • Physical characterization of meal (moisture content, particle size testing, bulk density) and pellets (moisture content, durability, hardness)
  • Comparison of information to industrial standard references collected by Tecaliman

During the test

  • Call out to site
  • Production tool assessment (steam circuit, press)
  • Discussion with press operators about pelleting management

Post-test

  • Edition of a study report
  • Establishment of industrial recommendations

Example of results

Factory not satisfied with its durability and identification of the principal source: impossible to raise the temperature on certain feeds (See table).

Recommendations

  • Installation of an additional boiler in order to provide steam in sufficient quantity to minimise carry-over.
  • Heating of the headbox of the boiler to 60°C at least to optimize boiler output.
  • Reduction in the proportion of large particles in the feed in order to minimise breakage points and pellet breaking

Contact

s.rouchouse@tecaliman.com – Tél. : 02 72 74 90 93

Homogenisation capability test

Requirements

  • Evaluate the capability of a mixer with respect to regulations
  • Modification of industrial practices or equipment settings
  • Evaluate the effect of unit operation on homogeneity
  • Study compatibility of an active product with a matrix with respect to homogeneity
  • Evaluation of production lines with respect to regulations

Service

Pre-test

  • Definition of the test objective
  • Definition of the test objective
  • Observance of rules set out in collaboration with the DGAL (technical data sheet no. 30)
  • Provision of a ready-to-use kit (protocol with station description, pre-labelled jars, batch dry mix)
  • Test cards to be completed and returned with samples

During the test

  • Call out for organization and management of tests on site
  • Contact by telephone if in doubt (if information before the date of the test)

Post-test

  • Sample processing (separation)
  • Analyses (RF-blue lake microtracer) or dispatch of representative samples to an external laboratory (tests not included in the contract)
  • Physical analysis of the meal tested (particle size testing, bulk density, angle of repose)
  • Edition of a report
  • Comparison of results with data acquired by Tecaliman
  • Evaluation of the results with the industrialist
  • Establishment of industrial recommendations on the basis of the results, profile, and method of implementation of the test

Example of results

Recommendations on the basis of the results (values and profiles) :

  • Cross-contamination before mixing may explain the low recovery rate
  • Homogeneity non-compliant but acceptable in relation to the point of addition of additives in the mixer

Contact

v.quemeneur@tecaliman.com – Tél. : 02 72 74 90 95

Carry-over test

Requirement

  • Evaluation of production lines with respect to regulations
  • Product comparison
  • Modification of industrial practices or equipment settings

Service

Pre-test

  • Definition of the specific objective
  • Establishment of the protocol according to the objective (choice of tracer)
  • Observance of rules set out in collaboration with the DGAL (technical data sheet no. 29)
  • Provision of a ready-to-use kit (protocol with station descriptions, pre-labelled jars, batch dry mix)
  • Test cards to be completed and returned with samples

During the test

  • Call out for organization and management of tests on site
  • Contact by telephone if in doubt (if information before the date of the test)

Post-test

  • Processing of samples (grinding where applicable, remixing, separation, grouping)
  • Analyses (RF-blue lake microtracer) or dispatch of representative samples to an external laboratory (tests not included in the contract)
  • Physical analysis of the meal tested (particle size testing, bulk density, angle of repose)
  • Edition of a report
  • Comparison of results with data acquired by Tecaliman
  • Study of the results with the industrialist
  • Establishment of industrial recommendations on the basis of contamination levels, profiles and method of implementation of tests

Example of results

Recommendations on the basis of the contamination profile of 2 manifold batches:

  • Inter-batch transfer with the upstream circuit of the mixer for origin essentially
  • Elevator to be adjusted at mixer exit
  • Detection of a source of inter-batch transfer by cleaning at the end of the batch

Contact

v.quemeneur@tecaliman.com – Tél. : 02 72 74 90 95

Residence time distribution

Requirements

  • Distribution of residence time of particles within a process
  • Modification of industrial practices or equipment settings

Service

Pre-test

  • Definition of the objective of the test
  • Concerted drafting of the protocol according to the objective (quantity of tracer to be added, point of injection of tracers, frequency of sampling)
  • Observance of rules established by Tecaliman (Cards 53 to 56)
  • Provision of a ready-to-use kit (protocol with station descriptions, pre-labelled jars, tracer)
  • Choice of tracers: Maize cob coloured with red 2G, microtracer, Yttrium oxide …

During the test

  • Call out for organization and management of tests on site
  • Contact by telephone if in doubt (if information before the date of the test)

Post-test

  • Sample processing (separation, cob particle count)
  • Physical analysis of the meal tested (particle size testing, bulk density, angle of repose)
  • Edition of a test report
  • Evaluation of the results with the industrialist

Example of results

Distribution in continuous thermal treatment with the stained maize cob

Contact

v.quemeneur@tecaliman.com – Tél. : 02 72 74 90 95

Gérer la freinte

Besoins

  • Identifier les principales sources de freintes (écarts positifs ou négatifs physiques ou financiers) d’un site industriel de fabrication d’aliments
  • Définir les axes d’amélioration pour limiter ces risques d’écarts
Pour une usine de 150 000 t, un écart de 0.8 % peut représenter une perte de 225 k€ ; avez-vous estimé votre manque à gagner ? Comment procéder pour réduire cette perte, c’est l’objet de ce diagnostic élaboré sur la base de 4 années d’études sur des sites industriels et expérimentés sur d’autres

Prestation

Avant l’expertise

  • Planification du diagnostic (inférieur à une journée)
  • Transmission de documents

Pendant l’expertise

  • Interview de plusieurs intervenants de l’usine (Responsable achat, responsable usine, contrôleur de gestion)
  • Diagnostic basé sur plus de 160 questions ciblées regroupées en 7 étapes (Réception, Broyage, Granulation, …) et 8 thèmes

Après l’expertise

  • Remise d’un rapport résumant par étape les points forts et les points faibles du site avec les orientations à suivre pour réduire les écarts et des propostions de mesures à mettre en place
  • Possibilité d’accompagnement complémentaire par des études ciblées

Exemple de résultats

Le diagnostic est transmis à l’usine par un compte rendu d’une dizaine de pages résumé par un radar. Dans cet exemple, il montre que l’usine doit orienter sa prévention de freinte vers des mesures liées au broyage d’une part, et à la granulation d’autre part, se référant notamment à sa gestion du séchage-refroidissement. Cette usine devra mettre en place des études complémentaires pour mieux estimer ces pertes, notamment humides sur ces deux postes, car ne les mesurant pas ou mal, elle ne peut en assurer une pleine maîtrise.

 

Contact

s.rouchouse@tecaliman.com – Tél. : 02 40 67 51 21