plant maintenance services

Hygienic Valve Maintenance

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What We Do

1. Reduce Contamination and Recall Risk

A preventative maintenance presence reduces recall risk.

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2. Improve Process Efficiency

Equipment maintenance improves performance.

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3. Lengthen Equipment Lifetime

A preventative maintenance program saves product, equipment, and energy.

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4. Eliminate Carbon Emissions and Waste

An ounce of prevention is worth a pound of cure.

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Customers We Serve

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How the Process Works

1. Remove Valves from Line

Our expert technicians and our one of a kind process allows us to service numerous rooms and clusters during a single shutdown. We label and remove all of our target valves.Up to 1200 in a single weekend.

2. Inspect and collect data

When we service valves we offer more than the immediate fix. We collect usable data. Through our cmms, we record passed and failed seal states. With our data we can then create a report detailing your Plant fail rate and problem areas. We help reactive maintenance become predictive.

3. Remove Wearable Seals and Clean Valve

After Data collection, we remove all wearable parts from the valve. The valve is then sent to be sanitized, removing any product debris or bacteria build-up from pitted seals. Regardless of seal state, product build up that can occur in certain processes.

4. Replace Seals and Lubricate

After we pass or fail a seal, we replace all wearable parts on your valves. Regular maintenance lengthens equipment lifetime. Based on inspected data, we can create a pm program and catch problems before they happen. We provide all the parts and spares.

5. Reinstall Valves and Start-up Test

Our job isn't done when the equipment is serviced. We make sure start-up goes smoothly, and there are no leaks or automation issues with any replaced valves.

5 steps

How the process works

1. Remove Valves from Line

Our expert technicians and our one of a kind process allows us to service numerous rooms and clusters during a single shutdown. We label and remove all of our target valves.Up to 1200 in a single weekend.

2. Inspect and collect data

When we service valves we offer more than the immediate fix. We collect usable data. Through our cmms, we record passed and failed seal states. With our data we can then create a report detailing your Plant fail rate and problem areas. We help reactive maintenance become predictive.

3. Remove Wearable Seals and Clean Valve

After Data collection, we remove all wearable parts from the valve. The valve is then sent to be sanitized, removing any product debris or bacteria build-up from pitted seals. Regardless of seal state, product build up that can occur in certain processes.

4. Replace Seals and Lubricate

After we pass or fail a seal, we replace all wearable parts on your valves. Regular maintenance lengthens equipment lifetime. Based on inspected data, we can create a pm program and catch problems before they happen. We provide all the parts and spares.

5. Reinstall Valves and Start-up Test

Our job isn't done when the equipment is serviced. We make sure start-up goes smoothly, and there are no leaks or automation issues with any replaced valves.

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reduce recall risk

How we help you mitigate recall risk

How we help

- Replace pitted, inking, or failing seals harboring bacteria.
New seals create total line and air isolation to prevent cross-contamination.
- Inspecting and cleaning valves on a regular basis removes product debris from equipment surfaces
- Preventative allows for regular data collection to catch possible contamination warnings.

Why is it important?

Harmful bacteria or unexpected contaminates arise when wearable rubber parts become pitted or compromised to allow product or cleaning residue to harbor within the seal. Bacteria festers and grows if allowed to reside on equipment. ​

Deteriorating seals prevent complete sealing and line isolation. This allows cross-contamination from line substances leaking or open air access. We see an average of 71% fail rate on seals for a first time PM.

In 2019 2.1 billion USD was lost to food recalls, not accounting for brand and consumer confidence damage.

2.1 billion
Total lost in food recalls in 2019.
124
Number of recalls in 2019.
10 million
The average cost per recall.
Not accounting sales.
Efficiency

How we help create a more efficient process

How we help

- Replace pitted, inking, or failing seals causing line inefficiency.
- New seals create total line and air isolation to prevent leaking.
- Inspecting and cleaning valves on a regular basis catches untimely reactive maintenance.
- Remove product and time loss due to contamination.

Why is it important?

Inefficient Plants waste time, money, energy and product. Our valve and pump service can reduce inefficiency in your product lines.

Deteriorating seals prevent complete sealing and line isolation. This allows leaking which wastes product and power per product output. Additionally any  cross-contamination causes massive inefficiency in unused production and reactive shutdown.

Downtime can cost up toPlanned down time can reduce reactive maintenance and can be used to length equipment lifetime and improve performance.

$5600 /min
Downtime can cost up to $5600 per minute.
100 gal
Hygienic valve lines can leak up to 100 gallons per day in wasted product and inefficient energy expenditure.
1.51
If an energy efficient plant runs at 1, leaking or machine quality issues can cause a 1.51 multiplication of inefficiency
reduce Emissions and waste

How we help boost sustainability in your process

How we help:

- Replace pitted, inking, or failing seals causing energy inefficiency.
- New seals create total line and air isolation to prevent waste.
- Inspecting and cleaning valves on a regular basis prevents new machine production and additional emissions.
- Remove product and time loss due to contamination.

Why is it important?

Creating a sustainable process matters at every level. Automation can save equipment by enrolling in a Preventative Maintenance program. Replacing wearable seals saves metal equipment. On average 1.9 tons or carbon emissions are produced per every ton of steel manufactured, by servicing and extending this equipment, carbon emissions are being avoided.

Necessary food production creates a quarter of the world's emissions. Removing line efficiency, such as leaks and recalls means more product for less energy.

1.9 tons CO2
CO2 emitted per 1 ton of steel produced.
8 billion
Pounds of food wasted a year in the US.
25% emissions
Food production creates a quarter of the world's emissions.
lengthen equipment lifetime

How we help extend your equipment lifetime

How we help:

- Replace failing seals allowing metal to metal contact.Add lubrication the valve to run smoothly.
- Inspecting and cleaning valves on a regular basis catches untimely reactive maintenance.
- Empowering data to keep you ahead of the curve in production and maintenance.

Why is it important?

Deteriorating seals creates metal to metal contact resulting in equipment damage. ​

Automation valves suffering from wearable part damage can cease to work, forcing reactive maintenance. ​

Damaged equipment needs budget and time for replacement. ​

On average  first time PM customers see a 71% wearable part failure. 9% percent of these have already cause equipment damage, more than the inefficiency in product and energy.

1.9 tons CO2
CO2 emitted per 1 ton of steel produced.
71%
We see an average 71% fail rate on wearable parts on a first time service.
9%
9% of first time serviced valves contain damage to non-wearable parts