Case Study: Chocolate Process GAR-SEAL® PTFE Butterfly Valve and BIO-LINE ASEPT®
INDUSTRY
Food Processing – Chocolate
CUSTOMER
A major global confectionery group producing leading consumer branded products, with a focus on quality and customer satisfaction.
BACKGROUND
This customer’s facility in Germany processes chocolate products, and they had experienced historical issues with butterfly valves for critical processes whereby the valves were failing prematurely and replacement parts were only available on a long lead-time. Additionally they required higher performing sealing solutions for hygienic connections throughout the process, requiring a superior material that would provide an effective seal while being resistant to aggressive process and cleaning media.
CHALLENGES FACED
Cocoa and chocolate processing can be very critical because when the cocoa beans are cracked oil and grease are released, thus presenting major challenges for many traditional sealing materials. Additionally in several areas the process media is very abrasive, which causes further challenges for the process components and seals.
OPERATING CONDITIONS
Media: Chocolate and Caramel
Pressure: 10 bar
Working Pressure: 0.8-6 bar
Temperature: 113ºF (45ºC)
SOLUTION AND BENEFITS
Unsatisfied with the existing butterfly valves as well as their seals for hygienic connections, the customer worked closely with Garlock in 2013 to organize trials of both GAR-SEAL® PTFE Butterfly Valve (DN 80-150) as well as GYLON BIO-ASEPT® seals. With a key focus on process efficiency and reliability, the trial proved to be a great success with zero failures and no unscheduled downtime. Garlock’s products have now been chosen throughout the process because of their excellent performance, extended lifetime and compliance with required industry standards such as FDA and EN1935. The short lead-time and strong service support from Garlock also means that the customer is now able to order the products only when required thus reducing the need for additional inventory and avoiding associated costs.
GAR-SEAL® Butterfly Valve for Control, Throttling and Shut-off Duties
GAR-SEAL® valves are used extensively where corrosive, abrasive, and toxic media need to be reliably controlled. They are typically used for accurate control, throttling, and shut-off duties in a wide range of industries, including chemical, petrochemical, chlorine, paper, electro-plating, and more. GAR-SEAL® butterfly valves offer reduced maintenance requirements and increased operational reliability.
BIO-LINE ASEPT®
GYLON BIO-ASEPT® seals offer high stability and a specific elasticity. The seals are pre-formed and stress controlled to provide a solid seal when assembled in piping systems. Chemical degradation or brittleness will not occur under normal or even elevated process and sterilization conditions. GYLON BIO-ASEPT® gaskets conform to DIN 11853 (hygienic connections) and DIN 11864 (aseptic connections) and far exceed the performance characteristics of conventional elastomeric seals.
