When purchasing filters for critical processes, it is important to work with a supplier with the experience and technical knowledge needed to recommend the right product for your applications and troubleshoot issues should they arise.
This case study is just one of many examples where TFS has applied its technical capabilities and utilized its large network of manufacturing partners to deliver a solution to a costly filtration issue.
This customer is a large food manufacturer in SW Minnesota. The food processing plant involved in this cases study makes a variety of cheese products, such as single slices of American cheese.
The plant was using 400 and 800-micron liquid bags to filter the cheese after production and prior to packaging. These filter bags were changed after every run and then inspected for particles filtered to ensure the integrity of the bag.
The customer began experiencing filter bag failure (or bag rupture), which caused re-work and loss of product.
When a filter bag ruptures during a production run, the plant quarantines the batch and starts a QA process to determine whether they can re-work the batch (an expense of $11,00), or if they must discard the product altogether, which can cost as much as $30,000!
Are you experiencing similar challenges with filtration?
To have a TFS filter expert review your filter applications and partner with you to resolve immediate filtration issues and lower your total cost of ownership, CLICK HERE to complete a short form and let us know how we can help!
The TFS solution
When the frequency of bag ruptures increased, TFS was asked to review the process and filter bags used. While on site, TFS filter experts reviewed the filter bags that had failed and sent samples to the manufacturer for a thorough inspection.
After it was confirmed that nothing in the customer’s process had changed to cause the bag rupture issue, TFS arranged to have the filter bag manufacturer visit the plant to review the installation process. Upon their review, the manufacturer made recommendations to plant personnel on proper filter bag installation and made improvements in the stitching for the bags they were supplying.
Despite these adjustments, the bag failures persisted. TFS promptly identified an alternate bag manufacturer, described the concerns, and sent samples of the failed product to the new manufacturer, who then developed a bag solution with sturdier material and stronger stitching.
The new liquid bag filters went through a successful trial at the plant, which resulted in the customer moving forward with the new bag filter solution, and at the same price as the previous product.
No issues with bag failure have occurred since the switch occurred, so quality issues and costly re-work and wasted product have been eliminated. The customer has since begun partnering with TFS on other filter applications throughout the plant with the goal of lowering the total cost of ownership for their filtration.
To have a TFS filter expert review your filter applications and partner with you lower your total cost of ownership, CLICK HERE to complete a short form and let us know how we can help!
This blog was contributed by the Total Filtration Services Team.