Problem: Solved | Standard Operating Procedures for Efficiency & Stability

A Caloris dairy customer requested a review of their evaporator in preparation for planned maintenance of the turbofan and the evaporator, which feeds a spray dryer.

When our engineer arrived on-site, the evaporator was down due to unrelated issues at the plant. This was an opportune time to inspect the unit while it was idle. Over the ensuing days, he was able to observe the evaporator on water and on product.

The evaporator was running well. Our engineer checked for vacuum leaks, the health of the turbofan, pump seals and seal water, pre-distributor alignment and more. This thorough inspection revealed multiple typical maintenance issues that were easily resolved to provide incremental operational and performance improvement.

Meet The Engineer

Tom Schappeler

Tom Schappeler

Processing Engineering Manager

On the operations side, our engineer noted that plant staff were running the unit very conservatively in order to avoid any potential issues on their respective shifts. This overloaded the spray dryer and therefore reduced the plant’s powder production capacity.

In addition, the evaporator was “outrunning” the dryer. When the dryer feed tank filled up, the operators were recycling the evaporator discharge back through the evaporator feed balance tank, which caused major disturbances to outlet solids, ultimately reinforcing the desire to run the unit conservatively.

Our engineer strongly advocated for producing and enforcing standard operating procedures so that the evaporator would run at its designed capacity in conjunction with matching its output rate with what the dryer could handle. This will greatly improve efficiency, stability and overall production capacity of the entire operation.

Need Help Defining Your Standard Operating Procedures?

Caloris can help streamline your process and develop standard operating procedures for optimal results on your processing line. Contact Caloris at 410-822-6900 or to arrange a process assessment at your facility.


About Caloris

Caloris transforms process systems design for the better with unexpected, future-focused solutions that solve real operational problems. We engineer efficient, dependable and productive solutions that also improve environmental sustainability where practical. Designed with the end user in mind to drive plant productivity. Caloris offers evaporation, membrane filtration and spray drying process systems for food and dairy industries, as well as for water reuse and wastewater treatment applications. Both Caloris’ custom and pre-engineered packaged systems are designed to meet our customers’ specific concentration/purification needs utilizing the most cost effective and energy efficient technologies available. Whether concentrating dairy, food or juice products at a high-volume production facility, or processing industrial wastewaters to reduce transportation and treatment costs and recover re-usable water, Caloris provides a range of options and technologies.