Amidst reports of declining business confidence and reduced manufacturing output, a recognised industry expert is advocating a return to fundamental equipment maintenance strategies aimed at optimising energy utilisation within industrial processing facilities.
The recent Business Trends report from BDO, an accounting firm, has unveiled uncertainties for UK exporters, partly attributed to China’s faltering economic recovery and subdued growth forecasts for the Eurozone. With supply chain disruptions identified as a major factor contributing to the decline in manufacturing output, companies must explore ways to achieve more with fewer resources and enhance the energy efficiency of their existing equipment to remain competitive.
This viewpoint is shared by Andrew Peacock, Business Unit Manager at Alfa Laval, a specialist in process equipment. Andrew specifically emphasises the significance of proactive maintenance programs for crucial operational components, such as heat exchangers, to ensure optimal energy utilisation within manufacturing facilities.
“Heat exchangers and similar equipment may appear straightforward, but they play a vital role in sustaining the operational efficiency of a factory,” he explains. “Given their role in managing thermal energy transfer during plant operations, it is imperative to maintain and optimise their performance. In an environment where energy supply and costs remain unpredictable, the expenses associated with neglecting maintenance and coping with unplanned downtimes during operations could be substantial, resulting in unwarranted costs and uncertainty.
“These disruptions can divert company stakeholders from their critical day-to-day responsibilities aimed at improving equipment performance, which is even more crucial given the prevailing challenging circumstances. Collaborating with original equipment manufacturers (OEMs) can provide added assurance against potential component failures and costly factory shutdowns, as supply chain integrity and performance certifications are guaranteed – a level of assurance that third-party parts cannot offer.
Demanding schedules continue to create challenges for decision-makers and facility management teams at process plants, often causing delays due to administrative tasks associated with reaching out to multiple equipment suppliers for parts and maintenance services. According to Andrew, adopting a ‘one-stop-shop’ approach, coupled with on-site supplier assessments to inform planned preventive maintenance (PPM) plans, can alleviate this burden.
“PPMs are frequently the first casualties during economic downturns, but this might be counterproductive,” he concludes. “Sustaining an efficient and operational plant is crucial in challenging situations, further exacerbated by unplanned downtimes. Leveraging the expertise and reliability of larger suppliers can actually lead to substantial long-term energy savings, which could prove to be critical when navigating uncertain market conditions.
“For instance, customers might find it more challenging to carry out effective maintenance due to a lack of data regarding the longevity of parts and components. However, data-driven planning, supported by frequent visual inspections conducted by specialists, can result in improved energy efficiency throughout the facility, as well as more effective part procurement strategies and maintenance plans.
“It all comes down to a fundamental question – is the facility as energy-efficient as it could be? By engaging the expertise of OEMs, more transparency can be provided on performance issues and where overly stringent schedules can be streamlined to ensure consistent, efficient operations. In light of BDO’s latest report, professionals in the process industry should consider strengthening their partnerships with manufacturers capable of providing comprehensive inspections and feedback on PPMs, particularly if they aim to safeguard their businesses’ bottom lines.
For additional information on Alfa Laval’s heat exchanger service and support programs, please click here:
https://www.alfalaval.co.uk/service-and-support/product-services/plate-heat-exchanger-services/
https://www.alfalaval.co.uk/gphe-service
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