Quick and Efficient Resolution of RTO System Failure

At a company specializing in the maintenance and cleaning of regenerative thermal oxidizers (RTO), we understand the importance of a quick and professional response in the event of failures and stoppages.

Recently, we received a call from one of the leading pharmaceutical companies in the region, where an RTO system had stopped due to a technical fault.

Recognizing the critical nature of the situation for the continuation of production, we took immediate action. Below is a description of our approach to resolving the issue and restoring the RTO system’s operation, confirming our commitment to providing high-quality services. All procedures carried out meet the highest standards of the pharmaceutical and chemical industries.

Response and Approach

Immediately after receiving the call, we organized an inspection of the RTO device. We understand that every hour of downtime is critical to the production process, so we are committed to a quick and efficient response.

Just 20 hours after the inspection, once the RTO system had cooled down sufficiently for safe maintenance, we were on site with all the necessary equipment, ready to begin cleaning.

Cleaning process

Our RTO system cleaning work was carried out with a dual objective: to resolve the malfunction and ensure that every step complied with the highest standards.
We began by manually removing larger contaminants, enabling a more thorough and precise cleaning process.

We then used our IBS systems to vacuum contaminants from both the upper and lower sections of the RTO, ensuring the removal of fine particles and dust.

Inspection of the ceramic elements

The next step was the inspection of the ceramic elements, which are essential for the efficient operation of the RTO system. We checked their integrity and looked for any signs of wear or damage.

From the lower side, we first thoroughly cleaned the chambers manually and then vacuumed them using our professional IBS vacuum systems. The lower section is often filled with contaminants, as shown in this case.

We then performed dry ice blasting of the ceramic media from below — a technique that effectively removes contaminants from the small channels in the ceramic elements without damaging sensitive components.

This was followed by thorough vacuuming of the ceramic media after dry ice cleaning, removing all remaining residues and ensuring the cleanliness of the system.

Results and conclusion

Thanks to our expertise and commitment to quality, we not only cleaned the RTO system, but also ensured that every step of the process complied with the strictest standards of the pharmaceutical and chemical industries.

The result was a successful production restart in the shortest possible time, with no compromises on quality or safety.
Our intervention demonstrated that even in urgent situations, the highest standards can be maintained, ensuring that the company can continue its operations without interruption.

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