Cycle Time Improved and Maintenance Costs Reduced in Plastics Plant

GoalImprove process cooling system performance by reducing microbiological fouling, corrosion, and maintenance costs.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"Overview","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry: \u003c/b\u003ePlastic Plant\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication: \u003c/b\u003eClosed-loop Cooling Tower\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem\u003c/b\u003e\u003cb\u003e: \u003c/b\u003eOil-contaminated closed loop cooling water was black and carried a distinct rotten egg odor.\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;\r\n\r\n\u0026nbsp;","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: Chem-Aqua recommended flushing the dead legs and installing jumper piping to connect the supply and return lines and provide continuous circulation.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResult: \u003c/b\u003eChem-Aqua’s recommendations helped improve the plant’s production efficiency and reduced maintenance costs.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>A plastics injection blow molding plant in the Midwestern U.S. was experiencing high maintenance costs and production losses due to microbiological fouling in the 3,000 ton process cooling water system. The oil-contaminated closed loop cooling water was black and carried a distinct rotten egg odor. Total and anaerobic bacteria counts were consistently high; iron levels routinely exceeded 10 ppm, indicating severe corrosion; plugging and heat transfer problems in the cooling water led&nbsp;to maintenance, high cycle times, and quality problems.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Chem-Aqua recommended flushing the dead legs and installing jumper piping to connect the supply and return lines and provide continuous circulation. Two HPF Closed Loop Filters were also recommended to filter the system water down to five microns. The automatic backwashing HPF Filters provide effective filtration without the hassles and labor costs associated with bag filters.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results Achieved</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>The plant followed these recommendations with outstanding results. Microbiological counts, iron levels, mold cycle time, and maintenance costs decreased while product quality increased. &nbsp;Chem-Aqua&rsquo;s recommendations helped improve the plant&rsquo;s production efficiency and reduced maintenance costs.</p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/3f7e0589cf83479c94880495024898ba.aspx" alt="" width="802" height="492" /></p> <p><!-- /wp:paragraph --><!-- wp:image {"id":7157,"width":"546px","height":"auto","sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --><!-- wp:image {"id":7155,"width":"546px","sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --></p> <p>&nbsp;</p> <p><!-- wp:paragraph --></p> <p><em><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/288b979d0b44413a9f610a05822d651d.aspx" alt="" width="804" height="489" /></em></p> <p><em>CS3-001</em></p> <p><!-- /wp:paragraph --><!-- wp:acf/two-cols-text-ctas {"name":"acf/two-cols-text-ctas","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-none","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a2539a7d03","block_text_list_0_block_title":"","_block_text_list_0_block_title":"field_662a2573bc047_field_6629f36ac5d6b","block_text_list_0_block_excerpt":"","_block_text_list_0_block_excerpt":"field_662a2573bc047_field_6629f37dc5d6c","block_text_list_0_show_cta_button":"1","_block_text_list_0_show_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f386c5d6d","block_text_list_0_block_cta_button":{"title":"Download PDF","url":"https://www.chemaqua.com/en-us/wp-content/uploads/sites/6/2024/07/CS3-001.pdf","target":""},"_block_text_list_0_block_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f39cc5d6e","block_text_list_0_use_special_button":"0","_block_text_list_0_use_special_button":"field_662a2573bc047_field_663af6cb5a467","block_text_list":1,"_block_text_list":"field_662a2550bc046"},"mode":"edit"} /--></p>