A prominent egg grading company that produces all eggs for Sunny Queen was facing significant challenges in their egg washing process. As one of the few countries in the world with mandatory egg cleaning standards, Australia requires that eggs be washed using chemical solutions to prevent bacterial contamination. The company needed an efficient, cost-effective solution to ensure that the chemicals used in the cleaning process were accurately dosed and monitored.
Application: Chemical dosing for egg washing
Challenge: Reduce chemical waste, lower labour costs, and ensure accurate dosing for audits
Solution: Ds500+ pumps with precise dosing and automated tracking
Outcome: Lower chemical waste, reduced labour costs, and easier auditing with improved accuracy
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.
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.
Since the installation, the egg grading company has seen a dramatic reduction in chemical waste and labour costs. The automated dosing system has improved accuracy and eliminated overuse of expensive chemicals, with the company able to reduce the frequency of chemical orders. The payback period for the pumps was remarkably short, as savings in chemical costs quickly offset the investment.
The system has been running smoothly for over 9 months, and the company now benefits from efficient, automated chemical control and simplified auditing processes.
"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!