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Address Process Non-Uniformity

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What is Process Non-Uniformity?

A non-uniform process is defined as a situation where production irregularities occur. For instance, a resin purging process may yield material that retains excessive hydrocarbons residuals, or, a drying process could consume excessive energy due to poor solids handling.

A non-uniform process results in inconsistent operation that can be difficult to control, generate waste, create safety hazards, and ultimately yield excessive operation and maintenance (O&M) costs.

Process issues result in ratholing

Ratholing of material causing process issues.

Ratholing of material leads to using a hammer on the storage vessel

Flow problems from process non-uniformity are often resolved by hammering storage vessels, risking damage and downtime.

Process non-uniformity leading to dusting

Dangerous dusting as a result of issues with process non-uniformity.

Process tableting weight issues

Process tableting shows weight issues.


Why is Process Non-Uniformity a Problem?

Process non-uniformities can place an enormous burden on the manufacturing operation and downstream supply chain. These burdens can include:

  • Product inconsistencies
  • Safety risks
  • Equipment failures
  • Poor process availability
  • Increased labor costs
  • Erratic product quality
  • Reduced production rate
  • Environmental hazards
  • Unscheduled maintenance
  • Customer complaints

When & Where Can Process Non-Uniformity Occur?

Non-uniform processes can be the result of poorly operating equipment or system design. Unreliable flow through material handling equipment will negatively affect process uniformity.  Common bulk material handling processes involve:

  • Silos, bins, hoppers
  • Transfer chutes, conveyors
  • Drying, cooling, purging
  • Crushing, milling
  • Rail/truck loading/unloading
  • Dust collectors, process filters
  • Sizing, screening, scalping
  • Blending/mixing systems
  • Compaction/agglomeration
  • Packaging equipment
Jenike & Johanson engineer
Jenike & Johanson engineer

How Can Jenike & Johanson Help to Avoid Process Non-Uniformity?

Reach out to our experienced team of engineers who will provide consulting, testing and engineering services!

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