Soap Maker Bubbling Over on Eaton Filters

Eaton’s DCF-800 Mechanically Cleaned Filter has helped this soap maker achieve a final product that consistently meets purity goals and has allowed for a more productive and cost-efficient manufacturing process.
Problem: Impurities in the soap due to an outdated filtering process
Solution: Eaton’s DCF-800 Mechanically Cleaned Filter
Results: The final product consistently meets purity goals and the manufacturing process is more productive and cost-efficient
Background
While maybe not quite as frightening as the famous Alfred Hitchcock shower scene, just imagine the shock of stepping into a hot shower, unwrapping your favorite bar of soap, and discovering that it’s already dirty. It can happen. That’s because soap contains glycerin, which brings with it important moisturizing properties. During the manufacturing process, glycerin is heated and added to the soap formulation before it goes to final production. However, the heating needs to be precise with little margin for error. When it is not heated properly, the soap can turn brown and even form brown specks that are small but still very much noticeable, hardly the 99 and 44/100% pure that a good soap needs to be.

Challenge
For one of the world’s largest suppliers of bar, detergent and body soaps, meeting that lofty goal is imperative to success. Supplying virtually every type of soap made, the company on any given day will see some 25 different brands of soap rolling down its production line. Relying on an outdated heating and filtering process, the company often had to reroute soap back into the assembly line to remove the brown haze and specks caused by the improperly heated glycerin to ensure that quality objectives were always achieved.  The rerouting was necessary, but was inefficient, expensive and time-consuming.  Additional labor was also required. While the final product was eventually meeting purity goals, the soap giant very much wanted to clean up the process.

Solution
In doing so, they turned to Eaton Filtration and installed a DOFF 800 filtration system for a 90-day trial run. The DOFF 800, a forerunner of the newer DCF­800 filters, is often used for trials.
Both perform a self-cleaning action by mechanically scraping collected debris from the filter screen with a disc that moves up and down the screen, parallel to the liquid flow. Collected debris is then automatically purged from the collection chamber at the bottom of the filter.  This self-cleaning action is performed without halting production and provides the highest quality filtering under continuous demand. Because the screen is cleaned continuously, a consistently high flow rate is maintained.  Uninterrupted filtering by the DCF also helps ensure consistent temperatures— a feature essential to meeting quality objectives.

Result
Before the 90-day test was even completed, the soap company was already washing its hands of the brown mess and has since ordered two new Eaton DCF-800 filters.  “Removal of the glycerin impurities was very successful,” reports Bruce Law, regional sales manager for Eaton’s filtration business. “The test unit delivered everything that we said it would.”  As a result, Law believes the costly rerouting of soap will soon be virtually eliminated.  “It’s still too early to gather a measurable return on investment,” adds Law, “but based on the results of the trial, the number of bars of soap that the company produces, and the cost to rework an out of spec product, it strikes me that the payback is going to be pretty quick.”

DCF-800 – One actuator delivers simple, reliable operation with water-like liquids. Ideal where a low initial investment is a key Our unique circular cleaning disc design (MCF design shown) ensures intimate contact with the screen to thoroughly and uniformly clean the media

 
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Eaton Filters are Can Do Solutions – Customer Success Story

Metal Food Packaging : Eaton Filters are Can Do Solutions

“Eaton has been right there with us and I have been very impressed with that.”  Quality Control Manager


Problem: Manufacturing facility was relying on an antiquated paper filtering process, which was expensive, hard-tomaintain, and time consuming.Eaton’s MCF 824-Series Mechanically Cleaned Filter.
Results: 
An easy to use filter that practically eliminated paper costs of approximately $60,000 per year, realized maintenance and labor savings, increased operator safety, and reduced landfill waste.


Background

The largest supplier of metal food containers in North America prides itself on quality,customer support, implementing leading edge technologies,sustainable business practices,and lowering costs whenever possible. Partnering with suppliers that can best help meet those goals is another primary objective. With annual sales in excess of a billion dollars, the company’s containers are used primarily by processors and packagers for foods such as soup, vegetables,fruit, meat, tomato-based products, coffee, seafood, adult nutritional drinks, pet food, and other miscellaneous food products. A wealth of well-known manufacturer brands, large and small, rely on the company’s cans for the consistent delivery of  high-quality, high-grade consumable goods.

Challenge
The cutting and shaping of metals is an important part ofthe manufacturing process. According to the quality control manager at one of the company’s 28 manufacturing facilities whose process requires the use of lubricants to keep the metal cool so that it can beshaped properly and precisely. The lubricant, or coolant, also picks up metal shavings, oils,and dirt that occur naturally. A filtering process is required to clean the coolant and return it to the manufacturing line.  For years, the facility was relying on an antiquated paper filtering process, which was expensive,hard-to-maintain, and time-consuming.Paper costs alone were running about $5000 per month, says the quality control manager. “On top of that, the changing of the paper filters would take the operator about a half-hour to 45 minutes of his time to cut offthe paper with a razor knife,carry it down stairs and put it on a pallet, dispose of it, and mopup the mess,” he adds.

Solution
However, that’s all changed now thanks to the installation of new Eaton MCF 824-Series mechanically cleaned filtration systems.The system features a cylindrical stainless steel housing that contains a cleanable, permanent filter screen. Unfiltered liquids flow from the top down and from the inside of the media toward the outside. Impurities are deposited on the interior surface of the filter screen, and the clean fluid exits through an outlet. When the media requires cleaning, a spring loaded cleaning disc travels top to bottom inside the filter media,directing collected contaminants downward, where they are concentrated in the purging chamber for easy expulsion. The whole cleaning process occurs while the filter remains in service, eliminating or reducing the use of disposable filter bags,decreasing operator handling,lowering inventory costs, and decreasing waste disposal. The innovative, magnetically coupled driving technology that moves the cleaning disc – without the need for shaft or drive external seals – adds additional appeal tothe unique design.

Result
The quality control manager reports significant financial gains by practically eliminating paper costs. The old systems are still used, but only as a backup when the Eaton MCF 824 units are undergoing scheduled maintenance.“We have been very satisfied,”adds the manager. ”We’ve been running the systems for four years and Eaton has been very helpful with us in making the original change over and later updating the equipment with new parts over the years.“They even came up with abetter way of cleaning the MCF824-Series filters. So we were able to extend the life of the filters even further. We originally had to change the filters every four or five days. Now we can stretch it out to once every eight days. “Eaton has been right there with us and I have been very impressed with that.” Not to be overlooked, he notes,are the additional gains being realized in maintenance savings,labor savings, and disposal savings – which deems that the responsible management of the environment plays a significant role in achieving success.“Now everything is pretty much automatic,” notes the manager. “It’s a much better system in a variety of ways.”He is confident other company manufacturing facilities around the country could also benefit with the Eaton setup, which has effectively turned the filtering process from a can of worms into a can of corn.

 

Read more customer success stories from Eaton’s Filtration Business.

Eaton’s Newest Customer Success Story : Paint Manufacturer

The Eaton DCF-1600 mechanically cleaned filter was installed to remedy the problems associated with large particles and foreign fibers. The quality of finished paints improved while the company reduced process costs, and gained a safer and cleaner work environment.

Read the full success story today. Click to Read

Eaton improves biodiesel loading system | Success Story

Quality requirements are rising fast in the alternative fuel market and the final product has to conform to tighter than ever standards. A biodiesel manufacturer originally installed a vertical duplex cartridge unit to filter biodiesel from a storage tank into trucks and rail cars and turned to Eaton’s filtration business to improve efficiency and reduce costs. Read the success story on how Eaton’s MAXILINE industrial filter housing has helped this alternative fuel processor meet and exceed their filtration and financial goals.

Baggage-Free Eaton Strainers Make Perfect Landing at JFK – Success Story

John F. Kennedy International Airport

“The Eaton strainer has been operating at JFK airport for the last 15 years without maintenance or attention. The ruggedness and durability has been great.”

Christopher Gogola
Maintenance Manager, JFK Energy Center

Background

Located on Jamaica Bay in the southeastern section of Queens County, N.Y., John F. Kennedy International Airport has more than 30 miles of runway surface and occupies some 4,930 acres of land. Better known as JFK, the airport has seven operating airplane terminals and roughly 125 aircraft gates.

More than 90 airlines operate out of JFK, which also serves as the base of operations for JetBlue Airways and the international gateway hub for American Airlines and Delta Air Lines. The airport is the fourth largest hub for American and the sixth largest hub for Delta.

JFK handles close to 60 million yearly passengers, making it the world’s 12th busiest airport by that measure. The airport also serves as the work site for some 35,000 employees.

Challenges

All those passengers and employees are kept warm in the winter and cool in the summer thanks to a heating, ventilation and air conditioning plant with a cooling tower located in the central terminal area. The tower must operate efficiently 24 hours a day seven days a week through all weather conditions.

To ensure this critical function is ready, the tower needs a strainer system that can not only handle the full load of 25,000 gallons per minute running through the tower, but also be maintenancefree and automated. Because of space constraints, the strainers also needed to be the primary source for removing dirt and other impurities.

Solution

JFK eventually chose Eaton for the job and selected a Model 2596 36-inch fabricated, automatic, self-cleaning strainer. Designed for the continuous removal of entrained solids from liquids, the automatic backwash strainer ensures maintenancefree operation of the system.

“This strainer has handled the full load of our water continuously for years for the supply of power to all of JFK airport,” says Christopher Gogola, maintenance manager for the JFK Energy Center. “It is critical to us to be sure there is no interruption in the power supply to the facility. Eaton has been a key component in this endeavor.”

With an automatic control system constantly monitoring the strainer operation, cleaning is accomplished by an integral backwash system in which a small portion of the screen element is isolated and cleaned by reverse flow. The remaining screen area continues to strain thereby providing uninterrupted water flow. The efficient design requires only a small amount of the strained liquid to carry away and dispose of the debris from the strainer.

Results

Fifteen years ago, when the strainers were initially installed, Eaton’s engineers believed they had the precise design needed at JFK. That turned out to be a very good call, as the Eaton strainers are still delivering continuous, uninterrupted, maintenance-free service.

Gogola agrees, and noted, “The Eaton strainer has been operating at JFK airport for the last 15 years without maintenance or attention. The ruggedness and durability has been great.”

During that 15-year run, JFK has, of course, experienced delays and cancellations, unfortunately associated with any airport. Safely putting people and aircraft into the air and onto the ground practically dictates complications… especially so at one of the world’s busiest facilities.

Fortunately, all of those same people dealing with the delays and cancellations remained cool, warm and comfortable thanks, to a large degree, to the uninterrupted service of Eaton strainers