1Stainless steel fermentation tankDaily maintenance: prevention first, extending equipment life
Sealing inspection and maintenance
Key operation: Regularly check whether the inlet and outlet pipe joints, tank cover flange screws are loose. If there is leakage, tighten or replace the packing; When loosening the fermentation tank cover and hand hole screws, it is necessary to prevent deformation of the sealing ring.
Cost optimization: Use corrosion-resistant fillers (such as polytetrafluoroethylene) to reduce replacement frequency and avoid bacterial contamination or equipment damage caused by seal failure.
Calibration of safety devices
Key operation: Check the pressure gauge and safety valve monthly to ensure their normal operation; The supporting instruments (such as thermometers and pH electrodes) should be calibrated once a year.
Cost optimization: Early detection of faults can avoid safety accidents caused by overpressure and reduce maintenance costs.
Cleaning and disinfection
Key operation: Use a soft bristled brush to clean the tank to avoid scratching with hard objects; Immediately empty the residue in the tank after fermentation and perform online cleaning using a CIP system.
Cost optimization: Cleaning can reduce the corrosion of residues on the tank and extend its service life.
Lubrication and anti-corrosion
Key operation: Regularly check the oil level of the gearbox and replace the lubricating oil every 6 months; Carbon steel equipment (such as operating platforms) is painted annually for rust prevention.
Cost optimization: Regular replacement of lubricating oil can reduce mechanical wear, and anti-corrosion treatment can avoid replacement costs caused by equipment corrosion.
Discontinued management
Key operation: If the fermentation tank is not used for a long time, the remaining water in the tank and pipeline should be drained, and the screws on the fermentation tank cover should be loosened to prevent deformation of the sealing ring.
Cost optimization: Avoid condensation water corroding the tank and reduce maintenance costs during downtime.
2、 Troubleshooting: Quick positioning, precise repair
Abnormal tank pressure
Common faults: The tank pressure cannot be maintained or is too high.
Troubleshooting steps:
Check if the screws on the can cover are tightened and if the sealing ring is damaged;
Confirm whether the pipeline joints or valves are leaking air, and whether the mechanical seals are worn;
If the tank pressure is too high, check if the solenoid valve is malfunctioning or if the valve core is stuck.
Cost optimization: Timely replacement of seals can avoid the risk of bacterial contamination and reduce production losses.
Slow sterilization and heating up
Common faults: low steam pressure or insufficient gas supply.
Troubleshooting steps:
Check if the electric heating tube is burnt out;
Confirm if the steam filter element is clogged and needs to be replaced regularly.
Cost optimization: Regular maintenance of the steam system can avoid batch scrapping caused by sterilization failure.
Dissolved oxygen (DO) is too low
Common faults: Insufficient gas supply or clogged filter.
Troubleshooting steps:
Open the valve or increase the gas supply pressure;
Check the air filter and replace the filter element;
Confirm if the pipeline valve is leaking air.
Cost optimization: Optimizing the ventilation strategy can improve fermentation efficiency and reduce raw material waste.
Temperature control malfunction
Common faults: Sensor or instrument damage.
Troubleshooting steps:
Check if the temperature probe is inserted into the slot and if the cooling water is turned on;
Verify the thermometer or replace the faulty instrument.
Cost optimization: Accurate temperature control can avoid abnormal microbial metabolism and increase product yield.
Abnormal mixing system
Common faults: Abnormal operation or excessive noise of the mixing shaft.
Troubleshooting steps:
Check the heating condition of the mixing motor and confirm if the bolts are loose;
Check the wear of mechanical seals annually to avoid bacterial contamination;
If a double end mechanical seal is used, attention should be paid to changes in the sterile water level.
Cost optimization: Regular maintenance of the mixing system can reduce downtime and ensure production continuity.
IIIStainless steel fermentation tankCost optimization strategy: from details to the whole picture
Preventive Maintenance Plan
Develop an annual maintenance plan, including lubrication, calibration, replacement of vulnerable parts, etc., to reduce sudden failures.
Case: A certain enterprise reduced the failure rate of fermentation tanks by 40% and reduced annual maintenance costs by 150000 yuan through preventive maintenance.
Spare parts inventory management
Reserve commonly used spare parts (such as sealing rings, filter cartridges, sensors) to avoid downtime caused by waiting for spare parts.
Data: Optimizing spare parts inventory can reduce equipment downtime by 60%.
Operator training
Regularly train operators to ensure they are familiar with equipment principles and fault phenomena, and reduce misoperations.
Effect: After training, operators can independently solve 80% of common faults and shorten maintenance response time.
energy consumption optimization
Optimize mixing and ventilation parameters to reduce power consumption;
Use efficient heat exchangers to reduce steam consumption.
Data: A certain enterprise has reduced energy consumption for single batch fermentation by 20% through parameter optimization.
Life cycle management
Record equipment operation data (such as pressure, temperature, stirring speed), analyze equipment degradation trends, and plan for replacement or major repairs in advance.
Case: A certain enterprise extended the service life of its fermentation tank from 10 years to 15 years through lifecycle management.