Processing
Insights

Search

Results

Corrosion: how to prevent an everyday risk becoming a problem

Beverage Dairy Heat transfer Prepared food

Corrosion: how to prevent an everyday risk becoming a problem

Integrity testing enables you to detect signs of corrosion in your heat exchanger before they cause a breakdown, saving you time and money. Read more about how it works in practice, and how it helped one food producer avoid costly downtime.

Corrosion is a well-known risk when operating heat exchangers, especially when the foods and fluids inside have a high chloride or salt content.

Thin sheets of metal separate pasteurized and unpasteurized product inside a heat exchanger. If they corrode and a hole forms, cross-contamination can occur and compromise product safety and quality.

As with the old proverb “a stitch in time saves nine”, the trick is to detect the first signs of corrosion at an early stage – before they have caused a perforation or crack.

A number of integrity testing technologies are available to detect metal thinning in heat exchangers.

The traditional solution involves using water pressure to increase the pressure load in a system using a pump and closed valves. Instruments then measure any changes in pressure to determine if there is any corrosion in progress.

But as with various other detection applications, this can be a time-consuming process. It is also imprecise in pinpointing the exact position of the leak.

Alternative techniques like conductometry, ultrasonic testing and ultraviolet tracing offer different benefits, but generally also take time.

Another issue is the potential risk, in some cases, of tracing media residues remaining inside the heat exchanger after testing.

Gas is faster, cleaner and more precise

A benign and time-efficient route is to use tracer gas – a mix of hydrogen and nitrogen or helium. Tetra Pak offers advanced testing services based on a mix of hydrogen and nitrogen gas.

The mix of hydrogen and nitrogen is non-toxic, eco-friendly and non-corrosive. And unlike helium, it does not stick to equipment surfaces and porous materials, and is therefore residue-free.

Integrity testing with tracer gas works faster than alternative technologies. Downtime is minimal – at just 3-10 minutes per tested section.

The level of precision is so high that engineers can pinpoint the exact section of the heat exchanger where corrosion has occurred.

Tetra Pak’s hydrogen gas integrity testing equipment is so sensitive that when customers in Australia first started using it, they discovered multiple small leakages caused by corrosion before they became a problem.

“The leakages were tiny and had not yet compromised product quality. They were a surprise for our customers, but we were able to fix them quickly before they caused any damage,” says Martin Eliasson, Tetra Pak Marketing Manager.

“After seeing the results, our customers decided to sign up for regular integrity testing. If you want to sleep well at night and be sure your heat exchanger is corrosion-free, it can be a good idea to order an integrity testing plan.”

 

Take a closer look at our integrity testing video

Having trouble watching this video? Watch it here.

[/form]

Related reading:

Separators and sustainability: how the right equipment can reduce the dairy industry’s climate impact
The science of separation
A brief history of separation
Separate wheys: the role of separators in today’s consumer trends
Why cold milk separation is hot again
Watch Your Speed – Tetra Pak® Homogenizer 250
It’s not you, it’s me – Tetra Pak® Homogenizer 250
4 things to look for in a homogenizer
Devils and details – the technologies you need for great spreadable cheese
Spreading knowledge: everything you need to know about mayonnaise production
How to control the cost of mayonnaise and cold emulsion production
The great mayonnaise controversy
3 global food trends and the challenges they pose for mayonnaise producers
4 tips to help you choose the right high shear mixer
High shear mixing reduces the cost of mayonnaise production
How to achieve high-quality mayonnaise
New mixer paves way for geographical and portfolio expansion
How a regional beauty producer saved $70,500 on energy costs
A short history of mixing – from mortar and pestle to microns
The heat exchanger budget dilemma: why project and operational managers disagree
Product-to-product tubular heat exchangers: surprisingly versatile
New heat exchanger welding technique meets 3-A Standard
Quantum leap: the secret to optimum heat exchanger configuration
Buying and owning a Tetra Pak® Tubular Heat Exchanger is child’s play
The digital future of dairies: automation and its effects
Four health trends and how your homogenizer can help you capitalize on them
Common quality issues homogenizers solve
A day in the life of a super-efficient dairy separator
What on Earth do separators have to do with space travel?
Infographic: faster, greener skin care cream manufacturing
How airtight separators help solve the coconut challenge
Why standard steel won’t suffice for dairy separators
Do you need help to navigate the mayonnaise maze?
Why two-stage homogenization is best for tomato products
Fine-tune your homogenizer to boost quality of tomato products
The magic inside our tubular heat exchangers
Cook and grind: from rock-hard beans to paste in 15 minutes
How to choose the right mixing and blending process
Simulation and its role in improving your product quality
How to streamline production for formulated UHT dairy products
2 common powder mixing challenges – and how to solve them
Mixing: where ingredients become products
Reduce total cost of ownership for recombined milk processing by 30%
Yoghurt is booming – here is the best way to mix it
4 steps to perfect blending – with optimal yield and minimal losses
5 questions that hold the secret to the perfect product
How to scale up sauce production
Finished syrup production: success is sweet
How to dissolve sugar safely, economically and reliably
Continuous benefits: 4 reasons to consider in-line blending
Cunning innovation makes a stir in the soft-drink world
Beverages with bite: how to process drinks with particles
How to design the optimal heat exchanger setup for your needs
Minimize your food safety risks with floating protection system
Viscous products and heat transfer: 5 things to think about
Corrosion: how to prevent an everyday risk becoming a problem
Infographic – A brief history of heating food
5 troubleshooting tips for tubular heat exchangers
How to make better soup – with mathematics
Infographic – Food heat transfer basics
Lower your operating costs with preventive maintenance
How to choose the right heat exchanger
Case closed: the magic inside airtight separators
Reduce your pressure – reduce your energy costs
How to ensure separation enhances value in whey production
How a Bactofuge unit restored one dairy’s market share
Clarification: 5 things you need to know
Bacto basics: how to achieve top-quality dairy products
3 tips for keeping your separator clean
Film: the basics of separation in 1 minute
4 important questions about NIZO
Condition monitoring: everything’s under control
The importance of centrifugal separation for product quality
Why an airtight separator is best for product quality
How to achieve high-quality tea through separation
The basic workings of milk homogenization
Homogenizing lactic acid drinks: 4 things to know
The joy of soy: homogenization challenges and solutions
Wanted: a quick lab method for assessing RNGS shelf-life stability
Homogenization: the secret to longer life
Homogenization: what you need to know
9 ways homogenization improves beverage quality
The ketchup effect
How a dairy solved the problem of excessive creaming
Five tips for avoiding common homogenization mistakes
Why a tiny gap makes a big difference for homogenization
How to choose the right piston for your application
How a dairy giant cut CIP energy costs by up to 10%
3 things you need to know about the compressed air for your separator
Video: Best value homogenization in the long run
Discover the benefits of cold milk separation
Homogenizer guide: what to consider for minimum TCO
Good quality water improves separator lifetime and performance: 5 important facts
The secret to large homogenizer cost savings
The cream of the crop: how the separator sparked a dairy revolution
Five reasons to choose an airtight separator
7 things to know about separators
Homogenizer total cost of ownership: what you need to know
How to produce more – without increasing your input
Low noise separators – hearing is believing
Homogenizer buying guide – 6 things to know
Why Tetra Pak Homogenizers give you best value in the long run
Get ten years’ peace of mind with unique warranty
How a dairy saved €19,500 in annual energy costs