8 minute read
"Everything was more than we could have hope for"
In the 2022 issue of Bridge, we wrote about a modification line being constructed in Lapua to produce a new kind of technical biopolymer in collaboration with International Flavors & Fragrances Inc (IFF). Biodegradable polymer can be used to replace fossil-based ingredients and ingredients containing microplastics in a number of applications. In this issue, we’ll take a look at the preparation of the very first production batch and the phases of the actual test run.
Advertisement
First production test run in August 2022
The blasting of the rocky plot was carried out in autumn 2021, and the construction of the foundations started in February 2022. During the summer, the walls of the plant went up in quick succession, and everything seemed to be proceeding according to schedule. It wasn’t until late summer that it became
apparent that the original target – a test run in August – would not be achieved.
“The installation of the equipment and pipes took longer than planned. At the same time, our partners also had delays, so we all got some useful extra time,” says Aki Laine, Chief Technology Officer.
The workers in the quality control laboratory also breathed a sigh of relief. The analytics and work instructions for the new product were created partly on the basis of starch analytics and partly from scratch with the help of IFF, but there was still a lot of work to be done at that time.
”In August, we were still missing the new analytical equipment we had ordered for polymer quality assurance,” says Annaleena Stenman , Laboratory Manager.
New schedule for the test run: November 2022
The new plant was first tested in November 2022. The test phase involved running water through the various process stages as well as fixing leaks and other problems as they were found. The automation also needed some fine-tuning to ensure that the product would
move through the process in the desired way.
The first test run with the Austrian suppliers of the evaporator was an exciting experience for Process Engineer Miikka Laukkanen.
“There are two ways a man can feel truly alive: bullfighting or operating an evaporator with manual control,” says Miikka, as if he can’t quite believe what he’s done.
The laboratory was almost ready to start production in November, as the new analytical equipment had arrived and the work instructions were almost complete. The delivery of the spectrophotometer might even have broken some kind of record.
“I placed the order by email at 15.40 on a Thursday. The device arrived at our laboratory at 11 o’clock the next morning,” says Annaleena, once again expressing her gratitude to Noora Kumlander of Berner MedLab for her quick service.
However, the test run had to be postponed due to challenges related to the raw materials and the completion of the plant.
New schedule for the test run: December 2022
As usual, we relied on our IT wizard Esko Hagren to create the log book needed for the modification. Based on
Chemigate’s wishes, Hagren designed an application that could be used to provide step-by-step instructions for the manufacturing process as well as to record sampling and analysis results.
“This project emphasised the traceability of the raw materials, which was successfully integrated into the log book using existing systems. The application supports the documentation well and takes what we do to a whole new level,” Aki Laine says gratefully.
Although the project was already well underway in Lapua, there were still challenges with the raw materials. As Christmas preparations drew closer, the test run was postponed until early 2023. At this point, Miikka Laukkanen had to re-
new the duty rosters for the third time.
Annaleena Stenman had an additional challenge for production and maintenance: the freezer ordered to store the polymer samples was so large that it would not fit through the warehouse door. It was decided to place the freezer in a temporary location in the lobby of the new plant.
New schedule for the test run: January 2023
The chemical pumping could only be tested at the beginning of the test run week due to problems with the control circuit. Unfortunately, even this test did not go as planned.
“During the test, the volume measurement of lye did not work, so too much lye was added to the chemical test batch.
The end result was far too alkaline and had to be diluted with sulphuric acid to at least make it suitable for the sewage treatment plant,” says Miikka.
Finally, the first test run day dawns. Jani Alanen , the operator who has been practising polymer modification the most, is on holiday in the Canary Islands. On the evening before the test run, Miikka is sceptical, and no one believes that the tight schedule that Aki has planned can be maintained. And before the manufacturing can even begin, it turns out that the pessimists were right: the factory has unexpectedly run out of liquefied petroleum gas. In addition, two pumps break down on the first day. There are no spare parts for the pumps, but they can be obtained by dismantling the pump that receives the raw material, which has no further use at this stage of the production.
However, the early setbacks do not delay the start of the test run by more than six hours. And once up and running, the production starts to run better than even the optimists could have expected.
“The longest stages of the process –filtration and evaporation – ran like a dream. One pump was not pumping at the expected capacity, and this bottleneck had to be dealt with. In the end, however, we were ready on the day we were supposed to be,” Miikka says happily.
In the laboratory, the test run has a significant impact on employment, as close to a couple of hundred samples are taken and dozens of samples are an-
new modification plant has now proven to be fully functional. Regular production can only start once the various parties involved have completed the necessary commissioning tests, investments and product approvals,” says Aki.
Miikka says that the project was a great way to develop his professional skills:
“It has been a pleasure to be involved in the production and problem-solving at so many stages. We have been building so closely with Fimpec that the project has become a joint effort where it doesn’t even matter which company you work for.”
two ways a man can feel truly alive: bullfighting or operating an evaporator with manual control.
alysed. Everyone is also eagerly awaiting the results of the different process stages. The nitrogen determination does not go quite as expected, but there are no problems with the other analyses. Once the analyses are completed, the laboratory has only good news to report.
“We were prepared to accept results well outside the target values in the test run. However, the results from our own and from IFF’s laboratories showed that the product turned out exactly as desired,” Annaleena says with a satisfied look.
First production batch ready: January-February 2023
The delay of just under five months can be considered a good achievement – at least if you ask the workers of Olkiluoto. After many sleepless nights and plenty of sweating, the first-rate biopolymer is ready to be dispatched via global partners to be used, for example, in the manufacturing of detergents.
“As far as Chemigate is concerned, the
“Project Manager Arto Haapanen from Fimpec retired during the project at the end of 2022. However, he brought the project to the finish line with solid professionalism and was still working at full speed in Lapua even during his retirement coffee. The close cooperation with Fimpec will continue with other projects, and even Arto might participate in the most interesting projects after his retirement,” adds Aki.
Even the laboratory freezer finally made it to its home in the warehouse after a few stairs were dismantled. Annaleena praises the coordination in establishing quality assurance practices:
“Without the work and support of our colleagues at IFF, we would not have been able to get the analytics done in this timeframe. The reference analyses between the laboratories quickly helped to identify critical areas for improvement. The equipment suppliers were also unexpectedly accommodating in terms of delivery times, which helped us significantly.”
It seems that the saying “everything was more than we could have hoped for” is appropriate here. We would like to thank all our partners involved in the project!
