Enhancing Safety and Efficiency in Biofuel Production at a Midwestern Processor

COMPANY BACKGROUND

A mid-sized beet sugar processing plant in the Midwest United States specializes in processing sugar beets into white sugar and liquid sucrose, along with coproducts such as pulp pellets and molasses. With annual production exceeding 1 billion pounds of pure white sugar. The company faced increasing regulatory pressures and operational challenges in handling water consumption and treatment within production operations.

THE CHALLENGE

The processor encountered significant issues with sealing systems in their sugar production line. The inability to reuse water and other products in multiple systems throughout the process reliably led to frequent seal failures. These failures resulted in leaks, equipment downtime, and safety risks, including potential chemical spills. The plant experienced multiple unplanned shutdowns per year, lasting 8-12 hours each, due to seal-related issues. Maintenance costs soared to $250,000 annually, and compliance with OSHA and EPA hazardous-material-handling standards was at risk. Traditional seals and sealing systems from other manufacturers couldn’t withstand the environmental needs and abrasive beet pulp residues, leading to accelerated wear and environmental hazards.

SEPCO’S INTERVENTION

SEPCO, a leader in industrial sealing solutions, was consulted after the processor’s engineering team attended a webinar on advanced sealing technologies for high wear applications. SEPCO conducted a comprehensive on-site audit, analyzing fluid dynamics, material compatibility, and operational parameters. SEPCO’s Sealing Professionals recommended a customized sealing strategy focused on durability, safety, and minimal maintenance to ensure “Safe and Reliable Sealing for Hi-Wear Production.”

SEPCO PRODUCTS IMPLEMENTED

SEPCO Dual Rotary Pumper (DRP): Cartridge-mounted mechanical seal that facilitates impeller adjustments, reduces power consumption, and maintains interfacial lubrication. It fits both standard ANSI sizes and process equipment, features a non-fretting, static O-ring, and multiple springs isolated from the pumped fluid. These seals feature tungsten carbide-silicon carbide faces and Viton elastomers, optimized for wear and high-temperature environments, providing zero-leakage performance under hazardous conditions.

SEPCO EXP Bearing Isolators: Applied to rotating shafts to prevent contaminant ingress and lubricant egress, enhancing equipment longevity in abrasive settings.

SEPCO Seal Support System: Tank reservoirs, flow meters, and abrasive separators, used in conjunction with SEPCO seals to provide clean, cool, and reliable fluid to the seals. Enabling longer and more consistent operational longevity.

SEPCO Compression Packing (Style 560): Used in equipment moving slurries and high wear processes, can run in processes with limited flush water, made from proprietary carbon fiber for operating in extreme conditions.

The implementation involved a two-week phased rollout, including training for the processor’s maintenance staff on installation and monitoring.

Results and Outcomes

Post-implementation, the processor saw dramatic improvements:

Safety Enhancements: Zero seal-related leaks or incidents in the first year, fully complying with hazardous material regulations and reducing worker exposure risks.

Operational Efficiency: Unplanned downtime dropped by 85%, from 12 incidents to just 2 minor events annually. Production uptime increased by 15%, allowing for an additional output.

Money Savings: Annual maintenance costs plummeted from $250,000 to $50,000—a savings of $200,000. Energy efficiency gains from reduced friction and leaks saved an extra $30,000 in utility bills. Overall, the ROI was achieved within 6 months, with projected five-year savings exceeding $1.2 million.

Long-Term Benefits: Extended equipment life (seals lasting 3x longer than previous solutions) and scalability for future expansions, positioning the processor as a safer, more sustainable leader in the beet sugar industry.