An egg grading company that produces all eggs for Sunny Queen was facing significant challenges in its egg washing process due to chemical wastage and increased labour time. As one of the few countries in the world with mandatory egg cleaning standards, Australia requires eggs to be washed using chemical solutions to prevent bacterial contamination. To address these issues, the company switched from its previous system to 10 Ds500+ pumps for accurate, cost-effective chemical dosing and monitoring.
Challenge Solved at a Glance
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Application: Chemical dosing for egg washing
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Challenge: Reduce chemical waste, lower labour costs, and ensure accurate dosing for audits
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Solution: Ds500+ pumps with precise dosing and automated tracking
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Outcome: $85K annual savings, lower chemical waste, reduced labour costs, and easier auditing with improved accuracy
The Challenge
The egg grading company had been using a manual dosing system to add sodium hydroxide and anti-foam chemicals to the cleaning baths. Chemicals were dispensed via a timed dosing pump, and every 30 minutes, QA staff had to perform titration tests to ensure the correct chemical levels. This process led to high labour costs and considerable chemical wastage. With anti-foam costing $20,000 per IBC and being consumed monthly, the company needed a solution to reduce these costs. The existing system also lacked automated tracking, making it difficult to meet six-month audit requirements and ensure consistent chemical levels.
The Solution
Global Pumps supplied the Ds500+ smart dosing pumps to address the challenges. After evaluating several options, the team decided the Ds500+ was the best choice due to its precision, compatibility with the company’s existing Building Management System (BMS), and ability to track chemical usage digitally.
Ten Ds500+ pumps were installed, each connected to sensors that tracked sodium hydroxide and anti-foam usage. The pumps were set up to dispense chemicals according to pre-programmed logic and sensor inputs, ensuring accurate dosing.
This automated system removed the need for manual testing, minimised human error, and allowed for detailed digital records to be stored for audits.
The Result
Since the installation, the egg grading company has experienced a significant reduction in chemical waste and labour time. The automated dosing system has improved accuracy and eliminated the overuse of expensive chemicals, allowing the company to reduce the frequency of chemical orders. As a result, they’ve estimated an annual saving of $85,000.
The system has been running smoothly for over 9 months, providing efficient, automated chemical control and simplifying the auditing process.
"The implementation of the Ds500+ pumps has resulted in automated control over chemical usage. We would like to extend our appreciation to Global Pumps for their exemplary support throughout this project." -
Ian, Development Manager, Queensland
Is your chemical dosing process in need of an upgrade? Global Pumps offers a range of pumps for dosing applications, perfect for the food and beverage, mining, or pharma industries. Contact the Global Pumps team today by filling out our 'Contact Us' form and receive a free consultation!
