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Updated: Sep 27, 2023


Case Study Pharmaceutical Company


Challenge:

Case Study Pharmaceutical Company

A pharmaceutical company had a failure in their autoclave and for 3 days had to shut down the line to search for the source. When they finally narrowed it down it was too late, they had lost $100k worth of product.


They also shut down the heating aspects of their steam system in the summer and find that every fall when they start it again they have several traps that fail.


One loss of product cost company over $100k

Solution:

They installed pulse steam trap monitors on all traps and have a dedicated computer with the dashboard in view at all times to ensure instant awareness of any anomalies or failures. They proactively purchase a number of spare traps ready to replace the ones that fail every fall. They have them at the ready when they start using the heat again and instantly swap out the bad ones.


Throughout the year they are now able to have visibility in real time on all steam traps and the efficiency and health of the entire system.



“Looking at this system was the catalyst to looking at other ways we can be more sustainable”


Benefits:

  • Production lines are confidently able to run without worrying about failures interrupting process at critical times

  • They don’t worry about shutting down and starting up the system

  • They have noticed a significant reduction in their energy consumption

  • They are calculating the amount of CO2 emissions they have reduced and are going to be putting together a comprehensive sustainability mandate for their organization

  • They are using some of the money they have saved by not losing product to send needed medical supplies to third world countries




Updated: Sep 27, 2023


Case Study Chemical Company


Challenge:

Case Study Chemical Company

Chemical Manufacturing company pays a huge amount of money for their steam. They have not had a full steam audit for 3 years. They know they have had a number of closed failures because the failures destroyed heat exchangers but have no idea how many traps were currently failed open. They want to be able to plan maintenance better to fix closed failures before they destroy equipment and simultaneously fix open failures and cut their energy costs across the plant.


Heat Savings on Exchangers pays for the cost of solution and installation. ROI is almost instantaneous.

Solution:


Installing Pulse Steam Trap Monitors on all steam traps took 2 of their maintenance people 2 days. Avoiding even 1 close failure pays for those workers wages tenfold. Plus being able to schedule the time was much easier than having to adjust schedules to accommodate emergency fixes, and no production line downtime was needed.


They have a number of solutions that monitor their equipment, all the dashboards are displayed on a central computer monitor that is accessible 24 hours a day. They like that the Pulse solution runs on an independent highly secure network that doesn’t interfere with other apps and that failures are sent as alerts.



“Cutting energy costs is one of our mandates for the next few years. This is a great start.”


Benefits:

  • They are able to proactively fix closed failures and avoid the devastating consequences to their heat exchangers

  • One of their biggest costs is energy, reducing that cost will significantly impact their net revenue

  • Installers completed a full steam audit while implementing Pulse solution, the first in over 3 years

  • They don’t need to monitor the dashboard at all times as failures and even anomalies are sent via email

  • Automation and efficiency are goals for the entire operation, this is one more step towards that ideal





Updated: Sep 27, 2023


Case Study Food & Bev


Challenge:

Case Study Food & Bev

A large food manufacturing and processing plant has 193 steam traps. They use culinary steam, hvac, a permeate tank and a heat exchanger. They are the market leader in the aggressiveness of their sustainability standards. They have a hard time finding steam trap leaks as inspections are very challenging because of their location (very high up near the ceiling). They have stated on their website that they will be NetZero by 2025.



Expert auditors did install in 4 days. A failure was detected saving thousands of tonnes of CO2.

Solution:


Once they heard about the Pulse SaaS solution for monitoring steam traps they instantly knew they needed to have this solution throughout their plant. They hired a third party steam trap auditing company to come and do an audit and simultaneously attach monitors to every trap. The audit company is very fast, they are able to install anywhere from 30 to 50 monitors per day, anchoring devices securely and quickly assessing which side of the trap is the condensate side so temperature sensors are placed correctly. During the install/audit process they actually discovered and replaced a failed trap, potentially saving the company thousands of tonnes of CO2 emissions and helping them adhere to their strict ESG goals.



“We have set very ambitious goals for our sustainability standards. I believe everyone should”



Benefits:

  • Using an audit company to do the install allowed them to fill in details about the size, type and position of the traps so that they are very easy to find down the road when they fail.

  • This is a best practice approach as they ensure that all traps are operational and have an accurate baseline.

  • The CEO of this successful family owned business has made a personal promise to be the most sustainable in his market space. This solution helped him on his track.

  • They no longer need to send workers up to inspect traps which are located in dangerous positions. The monitors send data to their dashboard wirelessly and safely.




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