Lab audits for process optimisation

key Benefits

Ensure more precise and accurate data
Make informed decisions on how to optimise your process
Increase efficiency across the plant

What we offer

An opportunity to test your laboratory performance

Data is the driver that allows you to ascertain and improve product quality, process efficiency and environmental performance. You use that to make decisions about how you might adjust the process for optimum results. But if the data you’re using is unreliable, how can you trust the results? You can’t.

If the data is bad, the results might be worse. An imprecise or inaccurate reading of the Lime Saturation Factor (LSF), for example, might mean problems controlling your pyro process and a lower quality product. Poor quality could cost you customers – or worse. Is that a risk you are willing to take?

A lab audit will identify any weak spots in your laboratory operations, enabling you to tighten up practices and recalibrate equipment to get plant performance back on track.

Step 1

We’ll cross-check your samples in our state-of-the-art laboratory

Step 2

We’ll evaluate laboratory processes and equipment performance

Step 3

You’ll receive a report on our findings including recommendations for improvements

Your audit will be tailored to your plant, your lab setup and any particular concerns you may have. Typically, this will include an audit of all the main laboratory analyses:

XRF
Alkali
Sulphur
Free lime
Chloride
Fuel analyses
Sieving residues
Specific Surface area (Blaine)
Cement strength development
Cement setting time

More general areas, such as sampling frequency and procedures, sample preparation and quality control can also be included on request.

Before we come to your site, we’ll ask for a defined set of material samples from across the process to be split, with one half sent to us for testing at our state-of-the-art laboratory and the other half tested in the plant. We will then include a comparison of the results in your audit report, which will help identify any areas that may be a cause for concern.

On completion of the audit, you will be given a comprehensive report of our findings, including recommendations where improvements could be made, such as adjusting calibration curves for the XRF.

Ensure your data is accurate: Our lab audits are tailored to your process, according to your requirements and any concerns you may have. The audit will cover all the main analyses in the laboratory, including both chemical and physical tests. Once complete, you will know whether or not your data is accurate. You’ll also see where there is scope for improvement – and, critically, how that might affect your wider operations.
Make informed decisions: The more you know, the greater your potential to improve plant performance – and profitability. If, for example, you realise that you have inadvertently been creating cement with a higher than necessary Blaine, you could achieve significant energy and cost savings by decreasing grinding time. On the other hand, if you realise your product quality has fallen below expectations, you will be able to rectify that and generate a more consistent and valuable product.
Increase efficiency: Greater precision and an optimised process gives you the ability to increase production capacity and lower fuel and power consumption. Tighter control on the process will also increase consistency and stability, which has a positive effect on other energy-saving initiatives around the plant.

Sample splitting and preparation at FLSmidth laboratory in Denmark

Why choose FLSmidth to audit your lab?

We don’t just know laboratory equipment – we know the whole process. Our comprehensive process knowhow enables us to look at the plant holistically and make connections that others simply wouldn’t see. It’s a niche position – and one we’re happy to hold.

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