An eastern Iowa enzyme manufacturer producing industrial grade enzymes, both liquid and dry, used in several industries such as animal nutrition, biomaterials, biofuels, corn milling, detergents, food enzymes, personal care, cleaning agents and textiles.
Industry: Industrial Biosciences
Location: Eastern Iowa
Products Used: TTI Power Breather’s (TT-1, TT-3, TT-4)
Enzyme manufacturing is a highly technical, complex and automated process that requires attention to detail to ensure pure and quality product. Industrial grade enzyme manufacturing is a fermentation-based process that requires a tiny volume of inoculum (bacteria) immersed in a controlled medium that supports adequate and abundant enzyme growth. A bacterium, like Aspergillus niger, subjected to a carbohydrate based medium in specific and controlled conditions (i.e. pH, temperature, oxygen content and additional nutrients) that multiplies enzyme production. Once populated, the enzyme is separated from ‘dead cells’ and further purified through separation by both centrifugation and continuous filtration techniques. This process is costly, resulting in high margins, leaving minimal room for process interruptions. Achieving a smooth process requires a sound maintenance budget and schedule.
As part of routine maintenance that reduces process interruptions, the enzyme manufacturer’s equipment needs to operate as smooth as possible. As part of routine maintenance, hydraulic oil reservoirs that feed pumps and gear boxes need to be free of moisture contamination. Reducing moisture contamination is achieved by using ‘breathers’ to allow air flow while trapping free moisture. This enzyme producer had been experiencing shorter breather life while using DesCase’s DC-1, DC-3 and DC-4 series. They were interested in trialing a cost-effective replacement, to extend operating life in a high moisture environment.
After reviewing and understanding the enzyme manufacturing process, experts at TTI determined, based on sizing and direct crosses, that the enzyme producer should trial the TT-1, TT-3 and TT-4 series for 90 days. After the trial stage, TTI’s breathers provided a 20% longer service life compared to DesCase’s DC-1, DC-3 and DC-4 breathers. By extending service life, TTI helped reduce maintenance costs and process interruptions. The three breather styles also contributed to a more efficient solution, at a lower cost while improving daily operation and maintaining product quality.