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Case Study: Calcium Carbonate Processor Cleans Up With Durable Seeflex 040E Connectors

CaCO3 Rocom Case Study - Sifter 1 600 x 400

Minerals - Dust and Downtime Issues Solved on Mineral Sifter

Calcium carbonate is used extensively in building industry products, from cement to paint pigments to wallboards.

It is a fine, abrasive white powder which means calcium carbonate processing is notoriously problematic in terms of dust containment.

When one of the largest calcium carbonate processors in Romania had issues with excessive downtime because of flexible connector leakage and frequent wear failures, they looked to BFM® fitting for the solution.

 

 

The Challenge

The customer had a lot of dust, material loss and downtime-related problems on the sifters in the initial part of their process, after crushing and before milling. The old flexible connectors leaked constantly, and they wore out extremely fast, not even lasting one month. Product spilled out and piled up around the sifters, requiring frequent clean-up.

The maintenance team found the replacement of the worn connectors extremely time-consuming because they were all different sizes and had to be measured and cut to length. Then, to install the connectors, they were fastened via screwed hose clamps requiring considerable manual adjustment in difficult locations.

The downtime involved in this frequent replacement process and clean-up of spilled product was becoming extremely costly for the plant.

 

CaCO3 Rocom Case Study - Portrait - Before

The BFM® Solution

Local BFM® fitting distributor, Rocom, recommended installing BFM® fitting’s durable Seeflex 040E connector systems on each sifter inlet and outlet. They also suggested standardizing all diameters and connection lengths to be the same for ease of maintenance and inventory control.

The result in terms of productivity uplift has been dramatic. In the 5 months since the initial installation, the plant has experienced zero downtime for connector replacement as the initial connectors are still going strong. When they do require changing, the staff are now confident each connector changeover will take less than 30 seconds, with stock always immediately on hand no matter which connector needs replacing.

There has also been no dust leakage from the connector transitions so the overall plant environment is cleaner.

 

CaCO3 Rocom Case Study - Portrait - After

Benefits Achieved

BFM® Reduced Downtime Icon in BlueLess Downtime

There are going to be far less replacements and product clean-ups required, so downtime has been drastically reduced.

 

BFM® No Product Loss Icon in BlueNo Product Loss

The internal fit of the BFM® fitting has ensured there are no leaks so the product stays inside the process and the plant is much cleaner.

BFM® Durable Icon in BlueMore Durability

Although the product is abrasive,the Seeflex 040E is more durable so outlasts the previous connectors considerably.

BFM® Streamline Inventory Icon in BlueStreamlined Inventory

A dramatic reduction in dust in the environment has helped reduce the risk of a combustible dust explosion occurring.

 

Here's what the client said about BFM®:

 

“We are so impressed with the fact that there are no more leaks and that the BFM® connectors are lasting so well.

The product stays where you want it - inside the process – and overall, the plant is now much cleaner and operates much more efficiently.”

- Maintenance Manager

Case Study provided courtesy of BFM® Distributor ROCOM  (Romania)

 

Keen to see how BFM® could transform your plant?

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