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Orion FilterCare services case study: effect of surface area on rate of filtration (Seitz Orion 100)

Nigerian Breweries Plc, Nigeria (formerly Heineken) asked Envirogen Group to carry out an audit to assess the filter equipment condition, current process setup, including potential optimisation and effect of surface area on rate of filtration and the implications to ancillary equipment.

Our FilterCare solution is a range of service and support solutions designed specifically for Orion process filtration and process optimisation. Our journey started with us visiting for an on-site audit to ensure we fully understood their filtration process. Ultimately, we optimised product, process and equipment performance.

On-site process audit and comprehensive audit report

Our report highlighted specific issues and included a series of robust recommendations with full cost-benefit analysis for work that needs to be undertaken. Summary of issues highlighted:

  • Complete process data sheet for both the current filter set up and the increased number of elements post expansion (examining the effect of surface area on rate of filtration).
  • Highlighted poor condition on certain filter elements along with remedial works.
  • Incorrect and worn seals causing excessive leakage.
  • Two pressure gauge assemblies blown causing potential bacterial issues.
  • Inability to alter dose rate on body feed equipment, leaving site overdosing reducing efficiencies.
  • Evaluated all ancillary equipment including product pump, dosing pump and carbonation capacity.

The solution

  • Extended existing pack by supplying additional fully reconditioned plate and frame filters to increase product flow rate and batch volumes (addressing the effect of surface area on rate of filtration).
  • Additional lower runner supports supplied to the filter to ensure the additional elements didn’t cause any machine damage.
  • Supplied and fitted complete replacement hydraulic seal kit. All seals replaced including plate, frame, profile and end plate seals. In addition, all cylinder seals were replaced to prevent future break-down.
  • Replacement pump unit fitted to allow different products different dose rates allowing longer more efficient run lengths.
  • Installed flow indication for beer pump flow rate (with sanitary design from carbon steel).
  • Supplied two new pressure gauge assemblies with hygienic stainless-steel interfaces.
effect of surface area on rate of filtration

Key outcomes

  • Successful examination of the effect of surface area on rate of filtration and its implications on ancillary equipment – resulting in fully working optimised filter and production process efficiencies.
  • Significantly reduced risk of costly breakdowns and potential brewery closure.
  • Reduced operating expenditure (OpEx)
DOWNLOAD CASE STUDY PDF

For a free assessment to evaluate water treatment and process filtration solutions for your site, contact our team of expert engineers

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About the client

Nigerian Breweries Plc is the largest brewing Company in Nigeria with eight breweries and two malting plants. Its brands include Heineken, Star, Gulder, Legend, Life, Goldberg, Amstel Malta, Fayrouz, Malta Gold, and Maltina. Nigerian Breweries is a recipient of several awards and recognitions in other areas of its operations including product quality, productivity and innovation, health and safety, corporate social responsibility and sustainability.

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  • Downloads
  • Latest News
  • Contact Us
  • LinkedIn
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  • Products & Technologies
    • Reverse Osmosis
      • EcoRO
      • PureSep RO Plant
      • Eco MultiPro
      • LabPure
      • EndoTherm
      • Back
    • Ion Exchange
      • EcoDI
      • EcoPure
      • EcoSave
      • EcoSoft
      • SimPack
      • MinX
      • Back
    • Hollow Fiber Membranes
      • PureSep MF
      • PureSep UF
      • PureSep NF
      • Pilot Plant
      • Back
    • Sterilisation
      • PureChlor
      • UV Sterilisation
      • PureSec Electrochlorination
      • Back
    • Filtration
      • Process Filtration
        • Filter Cartridges
        • Filter Bags
        • Filter Sheets
        • Filter Housings
        • Straining and Sieving
        • UK Drinking Water Production
        • Back
      • Media Filtration
        • Metals Removal
        • Conventional Media
        • Back
      • Cake Filtration
        • Pressure Leaf Filters
        • Filter Leaves
        • Plate and Frame Filter (Orion)
        • Back
      • Back
    • Biofilter Systems
      • Modular Biofilter
      • Biotrickling Filter and Biofilter Systems
      • Biological/Biofilter
      • Built-in-Place Biofilters
      • Back
    • Biological Fluidized Bed Reactor Technology (FBR)
    • Modular Plant Solutions
    • Mobile Water Services
    • Rental Equipment
      • Mobile RO40
      • Mobile RO10
      • IX Polishing
      • Hollow Fiber Membrane Piloting
      • DWI Filtration Systems
      • Back
    • Reconditioned Equipment
    • All Products
    • All Technologies
    • Back
  • Filtration
    • Filter Cartridges
      • Depth Filter Cartridges
        • Melt Blown Filters
        • Wound Filter Cartridges
        • Alternatives for Resin-Bonded Filter Cartridges
        • UK DWI Filter Cartridges
        • Back
      • Pleated Filter Cartridges
      • Membrane Filter Cartridges
        • PES Filter Cartridges for the Food and Beverage Industry
        • PTFE Filter Cartridges for Pharmaceutical and Biological Industries
        • Back
      • Oil Adsorption Filter Cartridges
      • Active Carbon Filter Cartridges
      • Metal Cartridge Filters
      • Filter Cartridges for Porous Materials and Porous Media Filter Elements
      • Back
    • Filter Bags
      • Needle Felt Filter Bags
      • Monofilament Filter Bags
      • Multifilament Filter Bags
      • High Efficiency Filter Bags
      • Extended Life Filter Bags
      • High Capacity Filter Bags
      • Oil Adsorber Filter Bags
      • Water Absorber Filter Bags
      • Filter Bag Accessories and Auxiliaries
      • Back
    • Filter Sheets
      • Depth Filter Sheets
      • Lenticular Filters
      • Filter Paper
      • Back
    • Filter Housings
      • Cartridge Filter Housings
      • Bag Filter Housings
      • Sanitary Housings
      • High Flow Filter Housings
      • Lenticular Filter Housings
      • Custom Filter Housings
      • UK DWI Filter Housings
      • Back
    • Cake Filtration
      • Pressure Leaf Filters
      • Filter Leaves
      • Pulse Filters
      • Fabric Filter Cloth for Pulse Filters
      • Horizontal Sparkler Filter Plate Types
      • Filter Press, Plate & Frame (ORION)
      • Back
    • Strainers and Sieving
      • Basket Strainers
      • Self-Cleaning Strainers and Self-Cleaning Filters
      • Disk Filters and Disk Filtration Systems
      • Back
    • All Filtration
    • Back
  • Services
    • PureCare Maintenance Programme
    • Membrane Services
      • Membrane Services
      • Membrane Recovery
      • Membrane Replacement
      • PureSep MF (Microfiltration)
      • PureSep UF (Ultrafiltration)
      • PureSep NF (Nanofiltration)
      • Back
    • Plant Refurbishments
    • Rental Assets
    • Pilot Plant
    • Cylinder Exchange
    • Orion FilterCare Services
    • All Services
    • Back
  • About
    • About Us
    • Leadership Team
    • Capabilities
      • Total Water Solutions
      • 3D Modelling & Design Engineering
      • Dedicated Project Management Team
      • Manufacturing & Installation
      • Water Technology Service & Maintenance
      • Back
    • News and Blog
    • Back
  • Case Studies
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