Category: Case Study

  • Improving Milk Powder Drying with Hot Air Flow Monitoring by Leomi

    Improving Milk Powder Drying with Hot Air Flow Monitoring by Leomi

    Background:

    Milk powder production is a delicate process. Getting the drying part right is crucial. If the airflow during drying isn’t right, the quality of the milk powder can be affected.

     

    Problem:

    A leading milk powder manufacturer was facing issues. Their drying process was inconsistent. Sometimes the powder was too wet; other times, it was over-dried. They needed a way to monitor and control the airflow during the drying process.

     

    Solution:

    The manufacturer turned to Leomi for solution. Leomi provided them with their advanced hot air flow meters. These meters were easy to install and simple to use.

     

    How Leomi’s Hot Air Flow Meters Helped:

    • Consistent Quality: With Leomi’s meters, the manufacturer could see exactly how much hot air was flowing during the drying process. They could adjust it to get the perfect temperature and flowrate for optimum drying every time.

    • Easy Monitoring: The meters showed clear readings. The production team could check the airflow at any time and make quick changes if needed.

    • Cost Savings: With better control over the drying process, there was less waste. The manufacturer didn’t have to throw away batches that were too wet or too dry.

     

    Results:

    Thanks to Leomi’s air flow meters, the milk powder manufacturer improved their drying process. They now produce consistent, high-quality milk powder. They also save money by reducing waste.

    Conclusion:

    Leomi’s simple solution made a big difference. The right airflow is crucial for drying milk powder, and with Leomi’s meters, getting it right became easy.

     

    Download

  • Enhancing Energy Efficiency in Plastic Closure Manufacturing through Advanced Flow Measurement

    Enhancing Energy Efficiency in Plastic Closure Manufacturing through Advanced Flow Measurement

    Overview:

    A leading manufacturer of plastic closures (bottle caps) in India, facing intense market competition, sought to enhance operational efficiency by monitoring and optimizing energy consumption. The management team decided to implement the Leomi Insertion Thermal Mass Flowmeter for compressed air monitoring, a crucial component in their production process. This initiative was aligned with their objective to refine key performance indicators (KPIs) and reduce the per-piece cost of closures.

    Challenge:

    In the highly competitive plastic closures market, controlling production costs is critical. The client aimed to gain a precise understanding of the energy and power consumption of their compressors to directly influence the cost efficiency of their production line. Prior solutions they have thought of such as the Orifice Or Vortex flowmeter found unviable due to higher pressure drop incurs permanent energy loss year-on-year and lower turndown ratio unable to detect leakages and high manpower cost & higher time of installation.

    Solution:

    The installation of the Leomi Insertion Thermal Mass Flowmeter addressed these challenges by providing high sensitivity monitoring (better than 100:1) of compressed air usage. Also have NO pressure drop and easy installation and dis-assembly from pipeline. This flowmeter was seamlessly integrated into the existing SCADA system, enabling real-time measurements of the SCF/KWH and SCFM/KWH ratios. These metrics are crucial for assessing compressor efficiency and guiding management in strategic decision-making regarding energy use and operational adjustments.

    Results:

    The implementation of the Leomi Flowmeter led to several significant improvements:

    1. Enhanced Compressor Efficiency: By monitoring the SCF/KWH ratio, the company could identify efficiency losses and optimize compressor use, focusing on running a single compressor rather than alternating with a standby unit, thereby achieving substantial cost savings.
    2. Leakage Identification: The high sensitivity of the flowmeter enabled the detection of air leakages, which had previously gone unnoticed with the Orifice or Vortex flowmeter.
    3. Reduced Energy Loss: Unlike the Orifice or Vortex flowmeter, the Leomi model minimized pressure drop energy losses, saving an additional 1%-2% in costs.
    4. Cost-Effective Installation: The adjustable installation feature of the Leomi Flowmeter reduced inventory needs and installation costs compared to traditional flowmeters.

    Enhance Efficiency with Leomi Thermal Mass FlowMeter

     Conclusion:

    The integration of the Leomi Insertion Thermal Mass Flowmeter into the client’s manufacturing process for plastic closures significantly enhanced the efficiency of their compressed air systems. This technology not only provided precise data that supported strategic operational improvements but also contributed to direct cost savings by reducing energy consumption and enhancing compressor performance. The successful deployment of this solution exemplifies the potential of advanced flow measurement technologies in optimizing industrial energy usage and achieving cost-effective production.


    Download

  • Vent Process Gas Flow Measurement in a Reputed Chemical Industry, Gujarat

    Vent Process Gas Flow Measurement in a Reputed Chemical Industry, Gujarat

    Vent Process Gas Flow Measurement

    Problem

    To produce commercial grade 30% to 37% Hydrochloric acid use of HCL Synthesis unit having 2000⁰C Top fired Combustion chamber made from impervious graphite (steel jacketed) process Hydrogen & Chlorine.

    Unabsorbed HCL will then be taken to the Tail gas tower (TGT) for better absorption of all HCL traces & remaining gas is vented. Customer was facing a challenge to install a flowmeter for Vent gas having HCL trace gas (<5ppmv) & water vapor at very low velocity where NO solution is available.

    After studying thoroughly our expert proposes a customized flow solution with HALAR Coated sensor probe which can work well as wetted parts.

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter:

    • Can handle corrosive gas environments with long life.
    • Senses very low-velocity upto 0.2 m/s make this application easy.
    • High turn-down ratio of 100:1 ensures high rangeability.
    • No pressure drop
    • Works well even in high water vapors & moisture

    Application

    Vent process gas flow measurement in the Chemical Industry.

    Customer

    Highly Reputed Chemical plant, Gujarat

    Product

    LEOMI- 586, Flanged Thermal Mass Flowmeter with HALAR Coating

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    Leomi 586 is installed in the Vent gas in Tail gas Tower in different duct sizes from 6” (DN150) pipe to 16”(DN400) with flow rates ranges. Working well even in corrosive gas with high moisture conditions and at very low flow rates with excellent repeatability since May’2021 at customer site.

    Leomi insertion thermal mass flowmeter with halar coated probe
    Halar Coated Probe
    gas flow measurement with Leomi mass flow meter
    Installation in 400mm Duct

    Download the Complete Case Study


    Download

  • Aeration Air Flow Measurement in One of the Leading Pharmaceutical Industries, India

    Aeration Air Flow Measurement in One of the Leading Pharmaceutical Industries, India

    air flow meter in pharmaceutical industry

    Aeration Air Flow Measurement Problem:

    An Integrated pharmaceutical plant with various departments such as API bulk drugs, tablets, liquid syrup manufacturing facility has a variable load of effluent water with a wide range of toxic organic and inorganic effluent into the effluent treatment plant for processing. This poses a challenge to maintain DO levels with respect to aeration air injection for BOD,COD & TOC control as per regulatory norms for resuage.

    Air Blowers are operated on a fixed pressure control loop which creates a problem on inefficient DO controls. DO is a function of air flow not pressure. Efficient Dissolved Oxygen ( DO) control is a challenge to obtain without accurate aeration air flow metering. Ineffective DO control means loss of energy and insufficient bacterial growth for optimum BOD levels.

    Aeration Air Flow Measurement Solution:

    Leomi – 586 Insertion Thermal Mass flowmeter

    • Doesn’t require a shutdown for installation
    • High turndown down ratio of 100:1
    • No pressure drop against the existing flow meter installed saves energy cost
    • Allows leakage detection with better accuracy
    • No maintenance than the existing flow meter used.

    Application

    Aeration air flow rate monitoring for control of Dissolved Oxygen levels in Effluent primary treatment plant.

    Customer

    India’s biggest Pharmaceutical drugs manufacturing group, Gujarat.

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    Leomi 586 is installed in the main branch of the Aeration air from Roots Blowers on 12” (DN300) pipe with 1400 Nm3/hr flow rate working for 5 years satisfactorily. Customers have repeated orders for their new projects last year 2021.

    Air flow meter is applied in pharmaceutical industry
    application of air flow meter in pharmaceutical industry
    Leomi air flow meter box connected to device

    Download the Complete Case Study


    Download

  • Hot Air Flow Measurement for Optimizing Coffee Bean Roasting in Food Industries, India

    Hot Air Flow Measurement for Optimizing Coffee Bean Roasting in Food Industries, India

    Air flow meter in coffee production in food industry

    Problem

    In Coffee production process, Roasting is the most critical process on coffee beans. Where heat is transferred by air flow rate on coffee beans is crucial by which taste, aroma & color are developed by air through roast. It removes chaff & small particles from the beans during roasting. Air flow is a key role in controlling a roast. Too low airflow leads to Blowers high energy consumption & low quality of roasting with high impurities, Whereas high airflow potential leads to tipping, where the edges of the beans become scorched. Due to the intense heat, the outside of the bean burns before the inside has an opportunity to develop.

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter

    • High turndown down ratio of 100:1 instead of DP type ( 4:1)
    • No pressure drop, Works well even in high temperature & low velocity
    • High accuracy upto (±2%) against available DP flowmeter (±4% FSD)
    • Doesn’t require shutdown for installation & Adjustable
    • No clogging due to air laden dust
    • No maintenance than the existing flow meter used.

    Application

    Hot Air Flow Measurement for Optimizing Coffee Bean Roasting in Food Industries, India

    Customer

    Reputed Coffee Production Unit, India

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    Leomi 586 is installed in the square (1100mm) & circular duct ( 2000mm dia) of Hot air blower outlet Successfully working for since July’ 2021 with excellent repeatability.

    Air Flow Measurement in coffee production unit
    Air flow meter in food industry

    Download the Complete Case Study


    Download

  • Combustion Air Flow Measurement in Thermal Power Plant, India

    Combustion Air Flow Measurement in Thermal Power Plant, India

    COMBUSTION AIR FLOW MEASUREMENT IN THERMAL POWER PLANT

    Problem

    Captive Thermal Power Plant produces heat energy and electricity. Efficient operation of today’s thermal power plant depends largely upon accurate and repeatable measurement of primary and secondary air flow to coal mills. Combustion air plays an important role to maintain air-fuel stoichiometric ratio for optimal combustion of fuel in boilers.

    • Primary air has high volume at very low static pressure in large ducts.
    • Low velocity & high temperature from 150⁰C to 400⁰C from APH (Air preheater)
    • Differential pressure flowmeters (Aerofoil or Pitot-tube) don’t work at low flow rates.
    • Existing DP flowmeter has high pressure drop & low accuracy upto (3%-4% FSD).

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter

    • High turndown down ratio of 100:1 against 4:1 of existing installation.
    • No pressure drop, Works well even in high temperature & low velocity
    • High accuracy upto (±2%) against DP flowmeter (±4% FSD)
    • Doesn’t require shutdown for installation
    • No clogging due to air laden dust
    • No maintenance than the existing flow meter used.

    Application

    Combustion Air flow measurement in Thermal Power Plant

    Customer

    Reputed 200MW Captive Thermal Power Plant in Cement Plant complex, India.

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    Leomi 586 is installed at the ID Blower Fan outlet for Primary air flow into Boiler with rectangular duct of 1400mm X 1200mm and flow rates upto 1,20,000 Nm3/hr. It has been working for the past 10 years without any maintenance.

    Combustion Air flow measurement in Thermal Power Plant

    Download the Complete Case Study


    Download

  • Exhaust Hot Gas Flow Measurement in Cement industry, India

    Exhaust Hot Gas Flow Measurement in Cement industry, India

    Exhaust Hot Gas Flow Measurement in Cement industry

    Problem

    Energy is a major input in the cement manufacturing process & it is met by setting up a Captive Thermal Power Plant for efficient operations. The heat generated through Rotary Kiln preheater (PH) & After quenching cooler (AQC) exhaust hot gases for power generation. Around 30%-40% of the power requirement of the cement plant can be fulfilled by using this waste heat for power generation. It optimizes the overall production cost.

    • Exhaust gas is generated at very low static pressure in large ducts.
    • Low velocity & high temperature from 150⁰C to 400⁰C
    • Differential pressure flowmeters don’t work at low flow rates.
    • Existing DP flowmeter has high-pressure drop & low accuracy.

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter

    • High turndown down ratio of 100:1 against 4:1 of the existing installation.
    • No pressure drop.
    • High accuracy against DP flowmeter
    • Works well even in high temperature & low velocity
    • Doesn’t require a shutdown for installation
    • No maintenance than the existing flow meter used.

    Application

    Exhaust hot gas flow measurement in a reputed cement plant

    Customer

    Reputed Cement Plant

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system.
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    Leomi 586 is installed in the Exhaust hot gas after quenching cooler (AQC) in 2000mm with flow rates of 40000 Nm3/hr. Works excellent at a high temperature around 340⁰C operating and low velocity up to 0.8m/s.

    fitting thermal mass flowmeter in cement plant

    fitting mass flowmeter in cement plant

    Download the Complete Case Study


    Download

  • Biogas flow measurement & recording in a reputed Starch industry, Gujarat

    Biogas flow measurement & recording in a reputed Starch industry, Gujarat

    Starch plant

    Problem

    Starch products are produced from corn processing. The process effluent waste water produces Biogas as a by-product with the help of the fermentation process. Biogas produces waste-gas (Biogas flow measurement) used for heating boilers and generators for energy conservation.

    • Biogas is generated at very low static pressure approx. 800mmwc to 1200 mmwc.
    • Biogas generate with low velocity & contains high moisture content ( 3%-5%Vol)
    • Existing orifice/ vortex flow meter doesn’t work at low flow rates.
    • Existing orifice / vortex flowmeter creates high pressure drop so have to increase pressure by the blower system with additional investment

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter

    • High turndown down ratio of 100:1 against 4:1 of existing installation.
    • No pressure drop against the existing flow meter can be installed after the gas holder, saving energy cost by removing the blower system.
    • High accuracy against orifice/ vortex flowmeter
    • Works well even in high moisture content
    • Doesn’t require shutdown for installation
    • No maintenance than the existing flow meter used.

    Customer

    Highly reputed starch plant, Gujarat

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    biogas flow measurement

    Leomi 586 is installed in the biogas generation pipeline after a gas holding tank in 6” (DN100) pipe with flow rates of 600Nm3/hr range. Works even in high moisture conditions and at very low flow rates upto 3 Nm3/hr as well. Working trouble free since year May’2019 at customer site.

    leomi mass flow meter

    Download the Complete Case Study: Biogas Flow Measurement


    Download

  • Compressed Air consumption monitoring in one of the world’s largest textiles plant

    Compressed Air consumption monitoring in one of the world’s largest textiles plant

    leomi compressed air flow meter in india

    Problem

    Textile industry is complex in nature.

    • Air jet Looms & Winding Machines are major consumers.
    • Negligence in machine specification selection- uncertain compressed air demand
    • In Composite textiles – Synchronization is a big challenge for high & low pressure.
    • Existing Vortex & Orifice flowmeters unable to record low flowrate consumption.
    • Have high pressure drop upto 3 psig which creates an energy loss.
    • Unable to identify compressed air leakage in various departments.

    Solution

    Leomi – 586 Insertion Thermal Mass flowmeter

    • Doesn’t require shutdown for installation
    • High turndown down ratio of 100:1
    • No pressure drop against existing flow meter installed saves energy cost
    • Allows leakage detection with better accuracy
    • No maintenance than the existing flow meter used.

    Application

    Compressed air consumption monitoring and recording in air jet Looms & Winding machines.

    Customer

    World’s biggest Textile plant, Gujarat

    Product

    LEOMI- 586, Insertion Thermal Mass Flowmeter

    Why Leomi?

    • An ISO 9001:2015 company, Startup India recognized
    • German technical collaboration Engineered in India
    • India’s First In-house fully automatic wind tunnel calibration system
    • Product quality proven for more than 20 years installed worldwide.

    Installation Facts

    compressed airflow meter in textile

    Leomi 586 is installed in the main branch of the different departments on 12” (DN300) pipe with 6000 SCFM flow rate with isolation ball valve providing easy removal. They are monitoring more than 150 Airjet looms and winding machines and have been used by customer for more than 3 years. Solved consumption problems of different departments. Payback in less than 6 months.

    insertion mass flowmeter in india

    leomi 586 thermal mass flow meter

    Download the Complete Case Study


    Download