What is Debottlenecking Process?

Manufacturing plants suffer from various bottlenecks that in-turn result in underutilization of the available resources. This is where debottlenecking process comes to the rescue. Read on to know more. Given the rise in demand for biomanufacturing processes, there has been a rise in demand for the optimization of biomanufacturing plants. There are various processes in a biomanufacturing plant that can be tinkered with to attain different results. It is almost impossible to get the same output practically as it is computed theoretically. While in theory the conditions are considered as perfect, they seldom are in real life. Processes are tinkered with to get as close to theoretical value as possible. Increasing the throughput and improving the efficiency of a system is essential to increase its profitability. Sometimes, certain areas and equipment limit the flow of product during the process. These areas and equipment are known as bottlenecks in the plant. Debottlenecking is the process of identifying these bottlenecks and optimizing it so that the throughput and the efficiency of the plant increases. There are various steps to plant debottlenecking: -

• Understand the process - The first step of debottlenecking is to understand the process. You must know the operating conditions of the process before you can start troubleshooting. You must have detailed knowledge of the entire operation to arrive at the most efficient solution for bottlenecks.
• Examine the operations - The second step of the debottlenecking process is to examine the operations. You must examine all the parts of the process to figure out which parts of the process are causing the bottleneck. It is these parts of processes that have a maximum deviation from theoretical processes.
• Understand the limitations - Sometimes there are practical limitations that cause the deviation from the theoretical value. There are parts of the plant that cannot be made more efficient due to physical limitations. Trying to increase throughput in these parts may create a safety hazard. There may be practical maximum values of the system. Even if machinery may be able to handle more volume it might create a safety hazard. Tinkering with processes that lead to the creation of safety hazards should be completely avoided.
• Work with creative people - Once you have identified the problems and sectors that can be improved upon you should make a team of creative people and establish a think tank. Working on a problem without proper thinking may lead to missing opportunities. Think tanks will help you come up with the best possible solutions that might be unique. You should never let an opportunity pass.
• Eliminate the bottleneck - Once the solution has been arrived at, it is time to implement it. It can be as simple as changing system parameters or may require changing equipment or retrofitting the equipment such that it better matches the requirements of the facility. Debottlenecking is an essential process that allows the biomanufacturing plants to run at maximum efficiency all the time. Debottlenecking also helps prevents further congestion in the plant and is one of the important preventive measures. A bottlenecked plant can lead to a lot of loss as compared to when the plant is not bottlenecked. Hence, there should be periodic inspections to check for bottlenecked parts in the plant. Resource Box: - Ingenero is a leading engineering services provider who offers a wide range of engineering and operating services to manufacturing companies across the world and helps them improve their bottom line by ensuring better usage of energy sources.