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Emech/Komax System delivers High Flow Rate Steam/Water Heating Solution 18th November 2008  The Komax/Emech system has been successfully commissioned and proven on a new recycled water process that was undertaken in May 2008 by major US beef processor. The engineering team from this processor were instrumental in the development of the project and found that the Emech technology and its operation with the Komax Static Mixing Technology provided a superior value proposition (in terms of reduced maintenance costs and delivered accuracy and control performance over time) to other alternative direct steam water heating systems. The change to the process takes a 540Gpm ,one pass system and converts it to a recirculation system that now only passes to waste water at a reduced rate of 50-60Gpm. The recirculation recovery process, saves not only water, but reduces the temperature rise required for the recirculation water saving in the consumption of steam heating energy. The processes when fully implemented are reported as having the potential to save 100million gallons of water alone, and with the Cost of Water alone running at US$1.50 per 100 gallons, the water savings alone for the plant are expected to be around US$1.5million per annum. The heating, treating and disposal costs of the water for this program were NOT included in the calculated savings. Since its successful adoption, further similar water/energy efficiency programs have been completed in this beef processors sister plants and other industry players are also taking note of the opportunity for improvements. Contact Emech Control Ltd., if you wish to know more, or are considering implementing a High Volume Steam/Water Heating system for your plant. E-mail: info@emechcontrol.com  Improved pressure & flow control of Nitrogen Gas - 29th September 2008  CCM Chemicals Sdn Bhd headquartered in Malaysia (www.ccmchemicals.com) has for over 70 years been a leading chemicals manufacturing and marketing company specializing in Chlor-Alkali , Ammonia, Polyurethanes and a wide variety of other specialty chemicals to a large variety of manufacturing industries on a global basis. CCM Chemicals have 6 plants throughout Malaysia, Indonesia and Vietnam. When Emech Controls distributor, Mr. SK Tan from Advance Process Instruments Sdn Bhd presented the Emech Technology to CCM Chemicals in Pasir Gudang, Johor, Malaysia, the engineering staff were very receptive to the technology. The engineering team immediately identified the value that the characteristics of the F2 2-port ceramics disc (rotary shear action, corrosion resistant ceramic disc seats) based flow control valve and the Emech high speed ( ¼ turn in approx 1.2secs) and precise (rotational resolution of 0.03degrees disc placement) actuator could bring to improving the control of their production processes. CCM Chemicals chose first off to install the Emech system to improve the pressure and flow control of Nitrogen Gas to their production process and have been rewarded with a tighter flow control resolution and span of control leading to improved product consistency. Through utilizing the Emech electric actuator and in built electronic control, the customer has also removed the maintenance and tuning related issues that often plagued their older style pneumatic actuation and digital positioner systems.  Technicians from Advance Process Instruments (www.advancepi.com.my) were on-site during the plant shut down to help install the system and ensured a smooth transition for the plants adoption of this new technology. Mr. Suresh Matthew, Manager Electrical and Installation for CCM Chemicals has commented that “the ability to easily tune and control this entire process through a fully digital system and having the resolution of flow control provided by the Emech F2 valve and actuator combination on this Nitrogen Gas Circuit has added value to not only this process, the projects success will ensure that other opportunities for process improvements using Emech technology are now being considered in other areas of the plant. For example, we will implement the Emech actuator on the control of a special 8” Tomoe Teflon Coated Chlorine Gas Butterfly valve in the coming months. We expect to see improved resolution / control of Chlorine Gas through the customizable speed and 0.03 degree rotational accuracy of the Emech actuator” Intelligent Emech Actuator automates divert valve process for Engine Lube Oil, saving fuel costs and eliminating National Power Grid outages - 18th September 2008  Philippine National Power Corporation (NPC) in Iloilo, Southern Philippines operate a series of Power Generation Barges. Each of these barges houses a number of Electricity Generating Engines that are used to supply power to the National Power Grid. A number of years ago, NPC stopped using an old pneumatic actuation control system due to the unavailability of parts and the difficulty with high cost of maintenance of this old technology. NPC staff had resorted to manually setting the divert valve at start-up and changing it manually as the lube oil temperature in the generators began to heat up. Often, during start-up when the lube oil temperature reached 45degC, there was a failure of the operators to manually adjust flow to the cooling circuit on time, resulting in the lube oil temperature continuing to heat up to 65degC. On reaching this elevated temperature the power generating motor would automatically shutdown due to the over-temperature lube oil. Incidents of these shutdowns were occurring several times a month, disrupting power supply to the national grid. In an effort to avoid such shutdowns, manual operators would avoid the start-up heating up cycle and simply switch the divert valve to the cooling circuit. This process meant NPC was forced to run the engines on more expensive diesel fuel for a significantly longer period before the lube oil was hot enough to allow NPC to switch fuel sources to the cheaper bunker oil.  Technicians from Emechs Philippine distributor Macondray Industries went on site and installed the Emech actuator by implementing the valve stroke limiting function in software and running the system in closed loop temperature control mode with the Emech sensor. They set-up the Emech actuator to automatically position the divert valve to the heating circuit on start-up and once the lube oil reaches the set point of 45degC, the actuator begins to action the diverting of lube oil between the heating and cooling circuit to maintain the optimum operating temperature of the lube oil at 50-55degC. NPC have now achieved an outcome whereby the Emech electric actuation and control system runs with minimal maintenance and no operator tuning, operating automatically to optimise the control of lube oil temperature from start-up allowing NPC to minimise the use of more expensive diesel fuel vs. the cheaper bunker oil, and concurrently eliminating power disruptions to the national grid caused by the over-temperature shutdown of the generators. Emech F5 System reduces energy consumption and boosts performance in IsoTank Cleaning Process - 21st August 2008  Fuji Oil (Singapore) PTE Ltd, a subsidiary of Fuji Oil Japan, is one of the world's leading manufacturers and suppliers of cocoa butter equivalents (CBE), non-lauric cocoa butter replacers (CBR), lauric cocoa butter substitute (CBS) and specialty oils and fats to brand-name confectioners. The Singapore operation is a highly automated plant specialised in the neutralization, bleaching, fractionation, hydrogenation, deodorization and packaging of oils and fats. When Fuji Oil (Singapore) PTE Ltd were first introduced to the Emech Technology, they immediately recognised the potential for use in multiple areas of their plant. Their management team then chose their "Isotank Cleaning Process" as a first off process to put the Emech technology to test. Previously utilising direct steam injection into a tank, the process was prone to consuming more energy than required for the Isotank Spray Ball systems through heating excess fluid in the reservoir tank. Despite complex external process control software and hardware, the process was often failing to bring that tank fluid up to the specified temperature required by the cleaning system. Replacement of the previous system with an Emech F5 Steam/Water Mixer, the Isotank Spray Ball Cleaner heads are now supplied with an instantaneous supply of in-specification hot water at an accurate temperature whenever the demand arises. Mr Tan. Manager from Fuji Oil commented that "as a direct result of installing the Emech F5 system, we achieve in-specification, on demand hot water for our Isotank Spray Ball Cleaners. We have reduced overall steam consumption, and boosted productivity in this cleaning process. We also eliminated all the extra control systems and ancillary equipment that had previously been installed to try and make this cleaning process work for us. The straight forward installation and performance of the Emech F5 system, with support from Emechs distributor Advance Process Instruments Sdn Bhd (API) to assist in commissioning, has made this project a great success for Fuji Oil. We will now look at other projects with API and Emech Technology." Emech to attend World Brewing Congress in Honolulu, Hawaii - 10th July 2008  Emech Control will be attending the upcoming 2008 World Brewing Congress. The event is only held every four years, and will be held at the Hawaii Convention Center, Honolulu USA, starting on the 2nd of August 2008 through until the 6th of August. The World Brewing Congress brings together the international brewing community to discuss product advances and the latest in brewing technology.  The event is the focal event for the United States Master Brewers Association, the American Society of Brewing Chemists, the European Brewing Convention, the Institute of Distilling and Brewing and the Brewing Convention of Japan. Many of the worlds leading brewers will be in attendance. The event will feature two co-located events: a trade show exposition that Emech is proud to be exhibiting at, and secondly a technical forum where Emech has been granted the opportunity to present two technical papers. The papers presented by Nigel Bartlett VP Sales and Marketing, and John Mead Regional Sales Manager will provide Emech the visibility of our expertise and experience on a global stage. Meet with Emech Control at the show at our stand number 114 or to request a meeting time at the Expo click here. Update on the Ruth Burnett Alaskan Sports Fish Hatchery - 28th June 2008  The construction contract for the construction of the Ruth Burnett Sport Fish Hatchery, Fairbanks, Alaska has been awarded to Alaska Mechanical Incorporated, which will include Emech technology as the principle tempered water mixing technology for the entire plant.  This project has been under design and development for a number of years, to finally have visibility that the contract had been awarded is a very important milestone for the Emech business. The Emech Control product set forms a critical part of this projects water temperature control and delivery system and has been incorporated into the design by leading international engineering design company CH2MHill. Emech is proud to be associated with this initiative in conjunction with our USA based distribution partner, Birko Corporation. The timeline for completion of the project has the building to be erected before the harsh Alaskan winter sets in, allowing construction to continue indoors and commissioning of the entire plant to occur in spring 2009. "Securing our involvement in this project is a fantastic result for Emech" says Nigel Bartlett VP Sales and Marketing. "This is a great recognition of our technology from an engineering sense, and our business approach of working with consultants and customers to fully understand their needs, so that we can jointly deliver a superior solution." Emech solves issues surrounding scald tank and also improves efficiency - 9th May 2008 
One of Malaysias leading poultry processing companies, publicly listed Farms Best Foods (KUL:FARMBES), based in Melaka, Malaysia, consulted with Emech Control and Emechs distributor for the territory, about the difficulty they were having controlling their scald tank temperature using direct steam injection into the tank. The installed pneumatic system and plunger valves controlling the steam flow to the bath were slow acting, they were causing maintenance issues and the control loops were proving troublesome when it came to ensuring a consistent bath temperature at start-up and during production. Emechs local representative in the region supported a changeover of the existing valves and controls to an Emech F5 system. The single Emech solution provides in-specification scald tank water at pre-production start-up, and top up heating water during the production day for this part of the poultry plants process. With the previous in tank sparge heating process, at start-up the customer was required to wait 1 - 1 1/2hours before the bath temperature reached specification for production. With the Emech system the bath is ready for production to begin within 20minutes of system start-up. The customer previously supplied the bath with steam sparge pressure of 5-6 bars and the Emech system is requiring only 3 bars of steam pressure for heating up and maintaining the scald tank. The simple and effective use of an Emech F5 system provides the customer a solution to fix what was an existing control issue surrounding their scald tank. The customer commented "We now have an on demand, flexible tempered water supply system that can deliver in-specification water and control our scald tank throughout our whole production day. Through using the Smart Emech valve and actuator system in this way we have improved our overall plant effectiveness and resource efficiency. With this proven success, we are seeking to adopt the Emech system into other Energy Conservation and Resource Improvement Programs". Simple and effective closed loop steam flow for shell and tube heat exchangers 4th May 2008  A Poultry processor based in Arkansas, USA consulted with Emech Control about the difficulties they were having in gaining consistent in specification tempered water from their Shell and Tube Heat Exchanger system which was providing water to their processing baths. The installed pneumatic system and plunger valves controlling the steam flow to the Heat Exchanger were slow acting and invariably their ability to maintain a steady state control of tempered water to the bath was proving difficult to achieve through traditional sensors, pneumatic actuation and PID loop control. Emechs local representative in the region supported a changeover of the valves and controls on the Shell and Tube Heat Exchanger to an Emech actuator coupled with a v-port steam control valve. Closed loop temperature feedback to the Emech actuator comes from a customised version of the Emech sensor placed in the outlet pipe from the Heat Exchanger. After completing the simple installation and powering the unit up, the Emech system, operating in Local Temperature Control Mode featuring continuous sensor feedback to the 100% duty cycle Emech actuator which houses all the PID control functionality for the system, ensures the system is always active in providing a consistently accurate output from the Shell and Tube Heat Exchanger. The customer states these baths now operate at 208 deg F +/- 1 deg and because of the flexibility and speed of response the bath water can be heated up more quickly and maintained more accurately. The entire system, due to the core Emech actuator control block, is fast and responsive to varying inputs and system changes in draw-off. Emech technology incorporated into the design of the Ruth Burnett Sport Fish Hatchery 22nd April 2008  Tender documents for the construction of the Ruth Burnett Sport Fish Hatchery, Fairbanks, Alaska have recently been released to the market. This project has been under design and development for a number of years, having been developed from research undertaken via the State of Alaska Department of Fish and Games Experimental Fish Hatchery Project in Fairbanks. The project recently featured on Alaskan News when the first ground was broken for the development. http://video.aol.com/video-detail/hatchery-plans-to-be-presented-february-25/961445652 The Emech Control product set forms part of this new projects water temperature control and delivery system and has been incorporated into the design by leading international engineering design company CH2MHill. Emech is proud to be associated with this initiative and is responding to parties involved in tendering for this project through our USA based distribution partner, Birko Corporation.
Kerry Ingredients in Malaysia
(a division of Food, Flavours, Ingredients and Bioscience company Kerry Group Plc) were having difficulty maintaining consistent temperatures during their Clean in Place "CIP" cycles. Kerry Ingredients installed and tested an Emech F5 alongside their traditional plant hot water supply system. After a few days of running the "Emech Closed Loop Control" system supplying plant hot water, the architecture of the Emech electric actuation package inclusive of a steam/water mixing valve and integrated in valve digital temperature sensor, was recognised by the customer as providing a superior on demand and continuous supply of hot water for the plant processes covering their CIP circuits and 32 wash-down stations across the 6 floors of this ingredients production facility. The customer comments that variability of supply and the level of maintenance costs they incurred are a thing of the past, their production, CIP and clean-up processes can occur without delay, and in specification. Improved product quality and output from Emech system - 25th Febuary 2008  "Rikevita" the Malaysian subsidiary of Japanese multinational Riken Vitamin was having difficulty maintaining the tight temperature control required in their cake emulsifier ingredients cooking vessel. The 7 ton agitated cooking vessel is required to follow a tight tolerance range of stepwise temperature increments. The tight tolerances on temperature and the difficult dynamics of maintaining control using the steam jacket meant that the product was sometimes either overcooked or undercooked and overall production output and quality of product were being severely impacted. The medium for heating and control to the jacket of the cooking vessel was replaced with an Emech F5 Steam/Water mixer. The speed and accuracy of the delivered heating fluid is now precisely and incrementally adjusted to the Rikevita production recipe and the required production tolerances can be met. The customer has commented that "With the new Emech F5 hot water heating method, we can set our process to a specific operating temperature and accuracy is maintained. We now enjoy improved product quality and output, achieve great saving in energy and utility cost. The days of product quality issue is history". 
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