The magic formula: Improve product quality while reducing costs, energy consumption and downtime | Alfa Laval

The magic formula: Improve product quality while reducing costs, energy consumption and downtime

See how Pendik Nisasta San AS, Turkey, cut costs and increased product quality by switching to Alfa Laval Compabloc fully welded heat exchangers.

DATE 2022-02-03

By replacing shell-and-tube heat exchangers with Alfa Laval Compabloc fully welded plate heat exchangers, Pendik Nisata San (PNS) drastically reduced heat loss, raw material use and cleaning costs while improving product quality and colour.

 Driven by their goal of continuous improvement and innovation, PNS have looked for ways of meeting the challenge of increasing revenues and keeping their competitive edge in the starch business, without increasing costs. They turned to Alfa Laval who offered an innovative solution – replace a bulky, inefficient shell-and-tube with an Alfa Laval Compabloc.

Products

Alfa Laval Compabloc - high performance fully welded plate heat exchanger

  • Compact, flexible design
  • No gaskets between plates enabling effective operation with aggressive media at high temperatures and pressures.
  • Easy to inspect, service or clean
  • Heat transfer ratios 3-5 times greater than shell-and-tube heat exchangers.

 Alfa Laval Compabloc

Customer's voice

Using Compabloc in the heating process has proven to be a big success.

Ömer Faruk Balci

PNS production manager

About the company

Pendik Nisasta San AS (PNS), jointly owned by the Cargill group and the Turkish food company Ülker, are leading innovators in Turkey’s starch processing market. Since 1996, PNS has been delivering outstanding customer satisfaction and high quality starch products for use in food, confectionary, paper, glue and textiles.

Company challenge

To improve processes and stay competitive in the starch production world, PNS needed to cut energy waste and expenditure as well as increase process efficiency.

About the solution

Replace inefficient shell-and-tube equipment with an Alfa Laval Compabloc. This revolutionized the process, bringing the following revenue-boosting benefits:

  • Start up starch heating duration three times lower than with shell-and-tube equipment, leading to shorter start up time, better control of parameters and reduced energy expenditure
  • Reduced heat loss during the starch milk liquefaction stage
  • More efficient heat transfer and homogenous fragmentation, causing:
    - Improved product quality and colour
    - Reduced raw material consumption in
    rotary vacuum filters
    - Increased feed capacity of rotary vacuum filters
  • Easier operation and maintenance, leading to reduced labour and cleaning costs.
  • Compact equipment that can be installed anywhere and frees up space.