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  Emech™ Control Systems are recognised as the new industry standard for temperature control in the tanning industry and now enjoy installations throughout New Zealand, Australia and USA. Tanning & Wet Blue Process: ‘Wet-blue' is the intermediate stage of processing where the hide is converted from its raw state into a stable material which will not putrefy nor be attacked by bacteria. This process is the first stage of tanning and requires a high volume of water at critical working temperatures. Industry Temperature issues:
This can be achieved through incorporating...
Industry Solution:  The Emech™ system provides a solution to all of the industry issues as outlined above.
Temperature Solution: The Emech™ system uses the patented ‘swirl-mix' valve that incorporates a temperature probe at the point of mix. This feature combined with the closed loop controller provides an accuracy of the valve to within 0.5ºC (0.9ºF). The result is reduced "call time" and fast and accurate delivery of tempered water atthe drum. Utility Solution: The Emech™ F4 valve offers a high-flow valve solution (approx 3000 lpm / 780 gpm) that has a fast-action response and ‘swirl-mix' feature. This allows the required set-point to be achieved very quickly and a fast-fill to the drum. It also provides other production advantages:
Maintenance Solution:
Case Study : Te Aroha Skins, New Zealand  Soon after installing a new high-tech water temperature control system, a primary processor has reported several clear benefits including energy savings, water cost savings, labour savings and product quality improvements. The system was installed last January at Te Aroha Skin Processors Ltd, in the Waikato, to replace a problem-prone setup used to control water for tanning hides from sheep, cattle and deer. Water temperature is critical to protect leather pelts from shrinkage, cracks and poor chemical penetration. "The new system came with a guarantee that it would perform to exceptional specifications", says general manager Pat Bennett. "It seemed too good to be true". The previous system, though reputed to be the industry standard, had caused the factory managers and operating staff much concern for its inconsistency despite repeated expert servicing. Developed and supplied by specialized flow control company Emech Control, of Auckland, the new system comprises a very compact control valve and actuator. It delivers water for the tanning process at five or more different temperatures between 28 and 50ºC to a ±0.5ºC accuracy. Flow can range from 1000 to 1500 litres/minute. Even at the highest rate, correct temperature is achieved in 1¼ second whereas the old system took about 45 seconds. The previous system diverted water back to the boiler which often overflowed to waste. Now the diverter has been eliminated and $150 worth of diesel fuel has been saved each week. "We're saving up to 4000 litres of hot water per day", says Pat Bennett. "Metered water usage charges are about $120 less per week and waste water charges are down by around $150 per week. Time saving cuts about another $420 from labour costs each week. "So with total weekly savings of over $800, payback will be in less than three months. We're very, very pleased with the value for money", he adds.  Installing the new Emech system was simple and straightforward. A 100 mm diameter hot water feed pipe was replaced with a new 50 mm pipe which meets all requirements. The existing plant plc was re-programmed smoothly for the new system. Should the plc ever fail, the Emech actuator can operate independently. "It seems to us that this new system is well ahead of its time. Its performance defies logic", he says. He's impressed with the valve's ceramic disc technology and self-cleaning capabilities, and its operation is easy. He adds that Emech's service has been impeccable including frequent follow-ups to ensure total customer satisfaction. "The main benefit has been our new confidence in reliability", says Pat Bennett. "The old system was unreliable and this was a constant worry for our managers and customers. In the three months since we commissioned the new installation, we've seen no variations or problems of any kind". Case Study : Lowe Corporation, Auckland, New Zealand Significant savings has been achieved by a local processor by replacing an existing water mixing system with an Emech mixing system. "The biggest advantage is the mixing time, which with the Huni would take up to 2 minutes and now takes about 4 seconds" says Scott Mather, Production Manager, Lowe Corporation Onehunga. "This alone saves us about 1 hr per day of queuing time. Not to mention the estimated 30,000 plus litres of water that is re circulating to the hot water on a daily basis". Over the next few months, gas usage will be monitored to further evaluate savings produced.  
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If the temperature is too hot, hides can be scalded. This creates pelt shrinkage as well as creating visual ‘burn marks' which affect final leather quality. 
Processors experience "call time". This is the time taken to fill the drum with the required water. 
Typical plants operate pneumatic operated linear mixing valves. The pneumatic actuators are slow to respond to water pressure fluctuations and the linear valves are a high maintenance item as the gland packing seal becomes worn and requires regular replacement |
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