Apache Stainless Blog

10 Tools for a Successful Sanitary Vessel Partnership

Thu, 29 Sep 2022 19:50:17 GMT

As a manufacturer of custom vessels for essential industries, including pharmaceutical, life science, and healthcare, Apache provides processors with high-quality vessels with up-front technical collaboration, engineering support, and a solid compliance direction. We bring these 10 tools to Sanitary Vessel customers:

Technical Sales & Engineering Experts
Apache’s experts are proficient in ASME and other compliance engineering for custom pressure vessels. Our project engineering process guards the targeted outcomes of price, compliance, and delivery.
All ASME Shop
Apache is first and foremost an ASME shop, which means that all protocols follow ASME and other high compliance standards, from manufacturing, to certification to quality compliance.
Regulatory Compliance Legacy
Custom vessels that meet regulatory compliance is what we do. Apache has a legacy of manufacturing vessels for high-compliance industries, since 1975.
Process Control
It is the control over our processes that allows Apache to offer these highly specialized vessels manufactured to exact compliance specifications.
Heat Exchange Expertise
Our engineering experts are versed in heat exchange surfaces including conventional jackets, standard dimple, ½ pipe, 1/3 pipe, inflated dimple and internal coils.
In-House Metal Finishing Investment
Metal finishing including manual, robotic and chemical finishing are all in-house processes.
Project Management
Apache’s engineering team provides technical support and expertise on new vessel projects to ensure vessel compliance.
Dedicated Quality Assurance Team
Apache has a dedicated quality assurance department that focuses on full verification, testing, and documentation of compliance documents.
In-house Tests and Documentation
Numerous testing and processes are performed in-house by experiences and certified ASME technicians and inspectors.
Industry Experience
Apache has served sanitary industries with custom pressure vessels for over 40 years.

Apache upholds certifications including, ASME U Certificate, ASME UM Certificate, National Board of Boiler & Pressure Inspectors R Certificate, and National Board of Boiler & Pressure Vessel Authorization to Register Certificate. In addition to ASME, Apache is accredited in many other global standards.

3 Levels of Sanitary Vessels

Thu, 01 Sep 2022 15:05:07 GMT

Depending on the application, processors serving food or other hygienic industries have varying degrees of compliance requirements for custom vessels. When working with your custom vessel manufacturing partner, it is important to identify the level of sanitary compliance in the pre-engineering discovery phase.

Apache defines three categories of sanitary design to help customers with the type of sanitary specifications for construction and fixtures to meet the vessel’s process goals.

BASE LEVEL

The base level sanitary vessel is cleaned manually. Typical construction fixtures include threaded coupling, threaded dip tubes and ANSI flanges. Depending on the application, stock vessels may be used or modified. The material is 2B/Mill, or 304 or 316 stainless and is pickle passivated.

Customers use base-level sanitary vessels for waste tanks, hydrocarbon storage, food-grade applications, adhesives, and solvents.

MID-LEVEL

The type of sanitation is also a driver for more complexity in the design of sanitary vessels. In the mid-level category, components are removed for cleaning or COP (clean out of place).

Mid-Level sanitary vessel designs are constructed with 304 or 316 stainless material and feature mechanical finishing and pickle passivation or nitric passivation.

Sanitary fittings are specified in a mid-level vessel from tri-clamp ferrules and tube connections to NA connects, flush mount outlet valves and sight glasses.

Customers use mid-level sanitary design vessels for material columns, solvent tanks, collection vessels, extraction, expansion chambers, mixing and dispensing.

HIGH-LEVEL

The highest level of sanitary design vessel is automated to be cleaned-in-place (CIP). A 304 or 316 stainless material is specified for high-level sanitary vessels mechanically finished to less than 32RA (roughness average), with nitric and electropolish chemical finish.

The fixtures in this category are electropolished including tri-clamp ferrules, tube connections, NA connects, sight glasses, j-tubes, dip-tubes, and polished internal coils.

Customers using high-level sanitary vessels are involved in automated processing and manufacturing. Applications for high-level sanitary designs include WRI tanks, R&D lab equipment, heating, and cooling vessels and nutsche filters.

Each level of sanitary design can meet ASME UM, ASMEU, FDA, 3-A, CRN, PED, and BPE compliance requirements.

When exploring the project parameters for a custom vessel, our guide, “3 Levels of Sanitary Design Tanks and Vessels” , helps to drive conversations and specifications that will meet the vessel’s application, timing, and compliance requirements.

Apache Stainless Equipment Corporation manufactures stainless equipment for a range of hygienic industries. Apache uploads compliance engineering expertise in beverage, biotechnology, pharmaceutical, cannabinoid, food processing, and life science industries.

5 Insider Tips to Get Faster Delivery on Custom Small Vessels

Thu, 10 Feb 2022 19:46:24 GMT

Equipment customized to a specific process has its benefits to solve a particular need. With standard equipment, you may need to adjust your scope. It’s understandable that standard stock vessel solutions only solve for a few common applications. However, custom vessel solutions that solve a specific process may take significantly longer to spec out, design and manufacture than standard stock solutions.

Here are tips to help reduce lead times on custom vessel projects:

Incorporate stock heads and stock fittings into the custom vessel design. Apache offers numerous styles of vessel heads that are kept in inventory. Head sizes range from 9”, 12”, 18” and 24”. Heads and fittings that need to be specially ordered require longer lead times.
Customers who can provide a general arrangement drawing before Apache’s approval process will expedite communications and reduce engineering time to determine those parameters.
Leverage industry standard components such as pipe fittings, pipe flanges (150# ANSI flanges) in the component list of your data sheet or bill of materials. The supply chain for standard components is typically more favorable for availability and delivery. These are often more cost effective as well.
Use pre-engineered, previously purchased designs. Customers who can refer to or have a repetitive project can shave up to 3 weeks off engineering time for faster delivery.
Discuss pre-ordering long-lead components before the approval of drawings. Collaborate with Apache’s sales techs and engineers to get a head start on critical components that fall under long lead status. With the customer’s approval, these parts can be ordered as soon as possible.

On occasion, an application may be very close to a standard vessel option. Apache has worked with customers to provide modifications to standard designs that also speed up the delivery of the order. Stock tanks include conventional styles and vacuum applications, ranging from 9” diameter to 18” diameter, and 1 gallon to 37 gallons, with pickle passivated or electropolished finishes. All of Apache’s stock tanks are built to and stamped per ASME code. It is worth considering as a faster delivery option; however not all custom solutions can be achieved by making modifications to the stock vessel designs.

As a manufacturer of custom vessels for essential industries, including pharmaceutical, life sciences, and health industries, Apache works with integrators who add their process technology to equipment and end-users who know their process and need a solution. Conversations around delivery to essential industries are top of mind.

While delivery times are impacted by supply chain, labor shortages, and material availability, Apache will drive the conversation about delivery needs and will consult whenever possible on modifications that help to manage timing for your custom vessel project.

New E-Book: Design to Submission Road Map

Wed, 24 Nov 2021 15:32:00 GMT

Many of Apache's customers, come to us with a full specification outline to custom manufacture their tank or vessel. For pharmaceutical, life sciences and health industries, Apache often works with integrators who add their process technology to sanitary equipment supplied by Apache. We also provide vessel solutions to end-users who have process technology support or experience, and need a vessel manufacturer to help them meet their quality and compliance standards.

Specifications such as Fixtures and fittings are also part of the compliance engineered solution. When learning about the vessel's intent, we want to define what the process connection (or nozzles) are required, as well as the service for each nozzle. This will help to pre-plan the general layout and placement of the nozzles. For custom ASME or other standards, the nozzles that we use must be compliant-driven and support the pressure/temperature rating of the vessel.

In this e-book "Road Map: Design to ASME Submission", we offer project planning recommendations for vessels that require ASME or other compliance. It is especially helpful for engineers or purchasers new to the role of procurement of sanitary custom vessels and tanks. This detailed "road map" provides planning insight and knowledge to acquire custom-designed and manufactured ASME vessels with an understanding of compliance engineering.

It is very important to partner with a vessel manufacturer with expertise in the type of vessel and industry for the use of the vessel. In ASME applications, it is vital that critical staff, fabricators and welders be ASME certified. Experience as well as reputation are significant when working with inspectors, agencies and governing officials to keep the compliance process moving forward.

ASME is a leading developer of codes and standards in the mechanical engineering community. Apache has been ASME certified for over 40 years.

Read the e-book, and learn more about compliance, engineering and project management to meet goals and procure quality vessels that not only meet compliance standards, but project goals too.

Comparing Base, Mid, and High-level Sanitary Finishes [Infographic]

Tue, 31 Aug 2021 21:24:47 GMT

Categorizing levels of sanitary design is helpful to professionals new to compliance regulated industries requiring custom vessels because it bridges communications regarding standards and design requirements.

In hygienic applications, stainless equipment requires a sanitary finish which generally refers to a smooth, scratch-free, non-corrosive finish. The fineness of the finish, which determines its performance, is measured in RA (roughness average). The infographic illustrates the RA of different types of mill, mechanical, and chemical finishes. The smaller the RA reading in microinches (height in millionths of an inch), the smoother the finish.

When collaborating to qualify a project, we define a Base Level Finish as a 2B/Mill, 304 or 316 stainless materials that is pickle passivated. The welds are continuous and crack and crevice-free. This type of finish is paired with a Base Level Sanitary Design and is cleaned manually. Apache’s standard portable vessel line are an example of the base sanitary design and finish level.

A Mid-Level Finish is also composed of 304 or 316 stainless material and involves a secondary process of mechanical polishing greater than 32RA, with final finishing to include pickle or nitric passivation. The welds are continuous, crack and crevice-free, and are also ground flush and polished smooth to a specific RA. Sanitary fittings, mechanical polishing, additional passivation processes and a cleanable design with removable components are categorized as Mid-Level Sanitary Design features.

Providing the smoothest RA readings is an electropolished finish after a series of processes, including mechanical finishing to less than 32 RA, passivation, and nitric passivation, which are common for High-Level Finishes. The base material is 304/316 stainless. The welds are continuous, crack and crevice-free, ground flush and polished smooth to a specific RA designation less than 32RA. The sanitary fittings are also electropolished. Vessels with this level of specifications are typically cleaned automatically.

The specifications, construction and finishing of a vessel is often driven by standards and compliance requirements. All three categories, qualify for ASME UM, ASME U, FDA, 3-A, CRN, PED, BPE.

There are other factors that fall in these base, mid and high-level sanitary design categories, including construction features, processing applications and time to delivery. Download our e-book “Guide to Sanitary Design for Custom Vessels in Hygienic Industries".

Anatomy of a Sanitary Design Vessel

Mon, 30 Aug 2021 15:02:55 GMT

When evaluating a custom vessel manufacturing partner for a new project, consider the manufacturing capabilities and experience that support the vessel’s application and sanitary requirements.

All custom design stainless vessels for the food, life sciences, pharmaceutical and health industries require sanitary construction. It is the application and automation that drives the level of sanitary componentry.

In reviewing each new custom vessel project, Apache identifies the sanitary requirements to categorize the vessel into a base, mid- or high-level design. Apache offers a standard line of vessels that qualify for various regulatory compliance agencies. However, these designs are considered a base level sanitary design, especially because the cleaning of the equipment is manual. Apache identifies a mid-level sanitary design vessel as having COP (Clean Out of Place) components.

In the video, a custom vessel is animated to walk through characteristics and examples in the highest and most automated level of sanitary design custom vessels.

High-Level Sanitary Design Characteristics Include:

CIP (Clean in Place) Process and Components
Continuous, crack and crevice-free welds, ground flush and polished smooth to specific RA (Roughness Average) <32 RA
304 or 316 stainless material, mechanically finished to <32 RA
Electropolished and Nitric passivated finishing
Electropolished sanitary fittings, including:
- Tri-clamp ferrules
- Tube connections
- NA Connects
- Flush mount outlet valves
- Sight glasses
- Orbitally welded j-tubes
- Dip-tubes
- Polished internal coils
- Samples Ports
- Spray devices
- Control panels
- External thermal jacketing

Processes and application in high-level sanitary design vessels include heating and cooling vessels, mixing and processing tanks, WFI tanks, filtering and R & D lab equipment.

Certification requirements is an important part of the sanitary design criteria. Sanitary design standards include:

3A – A regulation of the design for processing equipment in the food and drug industries. A 3A certificate is proof of FDA compliance.

ASME U and ASME UM - A regulation of the design of boilers and pressure vessels, including traceability of materials, procedures, testing and documentation.

BPE – A standard within ASME that drives equipment design for the bio-processing, pharmaceutical and other hygienic required industries.

In qualifying design, safety, automation other application details, Apache will facilitate the required compliance for the vessel and provide well communicated delivery, cost and approvals required for a successful project.

Navigating Stainless Material and Finishes for Sanitary Vessels

Wed, 25 Aug 2021 19:28:43 GMT

Stainless Finishes for Hygienic Vessels are measured by an RA (Roughness Average) meter. Manufacturers of custom vessels for life science, health and pharmaceutical industries adhere to strict design parameters to maintain compliance in these industries. The RA is a standard for an average of peaks and valleys on the metal’s surface, measured in microinches. Here is the evolution of stainless material coming to Apache with RA designations as it is transformed into custom sanitary design vessels:

RA > 100 Mill Finish A Mill Finish has an unpolished, dull-gray, matte appearance. This material type is the basis for supply for all stainless-steel flat products as well as the basis for additional finishing operations. It is hot or cold rolled with an RA (Roughness Average) of more than 100 microinches, depending on the gauge of the material.

RA 15 – 40 2B Mill Finish 2B Mill finish is widely used in food, chemical and pharmaceutical equipment applications. It is corrosion resistant and has a typical RA range of 40 (7 gauge) to 15 (16 gauge) microinches.

RA 29 – 58 No. 3 and No. 4 Finish Mechanical polishing achieves these finishes. The No. 3 Finish uses a 120-grit abrasive and has a semi-polished finish with an RA range of 36 – 58 microinches. The No. 4 Finishes uses a 150-grit abrasive and has a polished, brushed surface. The RA range is 29 – 40 microinches.

RA 18 – 31 No. 4A Also identified as No. 4 Dairy Finish, this finishes is required to meet the basic FDA 3-A standards. It uses a 180 grit and has a RA range of 18 – 31 microinches.

< 32 RA Pickle Passivation Pickle Passivation often follows other manufacturing processes including welding and grinding. Also called Pickling, it is the immersion of the metal in a pickling bath or coating the material with pickling solution, such as nitric-hydrofluoric acid. The process removes both metallic contamination and heat-treating scales. Pickle passivated stainless steel has a matte appearance. Apache’s tests have confirmed improvements up to 25% in RA readings on material that has been pickle passivated.

Lowest RA Electropolishing Electropolishing is an electro-chemical process that removes surface material from stainless steel. The process includes an immersion of the stainless-steel component into a temperature-controlled bath of electrolyte that is charged with a DC power supply. Electrolytes used in electropolishing are concentrated sulfuric and phosphoric acid solutions. The finish has a mirror appearance. Apache’s before/after tests have shown improvements in RA smoothness up to 50%; results vary depending on stainless material.

In the highest level of sanitary design applications the vessel is pickled after manufacturing and polishing, then electropolished.

Here is our Guide to Stainless Material and Finishes for Sanitary Vessel applications.

VIDEO: The Affect of Manufacturing Processes on Stainless Surface Smoothness

Thu, 24 Jun 2021 17:22:58 GMT

The particular RA (Roughness Average) value is a requirement for stainless vessel manufacturing for federal, state or local compliance agencies across many critical industries. It is a crucial standard in these industries to maintain a clean system. The instrument used in the measurement is called a profilometer, which provides an average in micro inches. The smaller the number, the smoother the stainless material. It is common for high compliance vessels to have single digit RA readings on product contact surfaces.

In the construction of pharmaceutical, life sciences, or medical-use vessels, meeting the RA requirement may include several steps, including material selection, grinding, polishing and chemical finishing. Manufacturing processes can affect the RA measurement on stainless material, including forming, stamping and welding. In the video, we walk out of the manufacturing plant with our quality controls manager to show measurements on material in vessels being manufactured in various stages of production.

Pickle Passivation and Electropolishing chemical finishes have a high degree of improvement on RA smoothness compared to material before it is treated. Pickle passivation, also referred to as descaling, removes the scales and leaves a clean matte finish, free from contamination. Electropolishing is an electrochemical process that dissolves surface metal, removing all embedded contaminants and creates a smooth, mirror finish.

ASTM International (American Standard for Testing and Materials) is one of several standards that Apache upholds. ASTM A967 is the standard specification for Chemical Passivation Treatment for Stainless Parts. ASTM B912 is the standard specification for electropolishing stainless steel alloys. The ASME-Bioprocessing Equipment (BPE) standard was created for the pharmaceutical and bioprocessing industry. The BPE surface finish standard classifies surface finishes and the acceptance criteria for compliance.

In the business of compliance vessels, there are numerous standards that are required to deliver the necessary codes in any given project. Follow our videos, blogs and e-books developed specifically to help our processing customers understand the manufacturing and compliance process.

Video: 3 Levels of Sanitary Construction

Wed, 19 May 2021 18:32:20 GMT

Processors serving food or hygienic industries have varying degrees of compliance requirements for custom vessels solutions. The designation of "sanitary" has a wide range of definitions depending on the customer, the industry or the standard.

Since Apache provides custom engineering and manufacturing, we reference these levels to guide conversations so the precise specifications for compliance and function are met. This video is a brief overview how Apache defines base, mid, and high level sanitary vessels.

BASE LEVEL

Apache refers to a base level design as an entry-level, food grade, chemical and general use vessel. Base vessel sanitary construction is typically defined as continuous, crack and crevice-free welds. Fixtures are threaded, such as couplings and dip tubes, an may include ANSI flanges and Thermowells probes. Base level tanks and vessels are pickle passivated and are manually cleaned after use.

MID-LEVEL

In custom sanitary vessel discussions, Apache defines mid-level vessels as COP (clean-out-of-place) capable. There is a higher level of finishing on the inside dimension for mid-level criteria, and the construction fixtures are all sanitary specified, like tri-clamp ferrules, tube connection, NA connects, and sight glasses for example. Processes and applications for mid-level sanitary tanks include columns, solvent tanks, collection, extraction, mixing and dispensing.

HIGH LEVEL

The highest level of sanitary design vessels are designed with CIP (clean-in-place) processes. The finishing on high-level vessels are smoothly polished to less than 32RA (roughness average) on the inside of the vessel. The chemical finish is both nitric passivated and electropolished on high-level vessel designs. Customized high-level sanitary tanks have electropolished sanitary fittings from tri-clamp ferrules, tube connects, to orbitally welded j-tubes, and polished internal coils. Highly compliant and sanitary vessels are used for processing, WFI, R&D lab equipment, heat and cooling, and nutsche filtering.

For more information into the criteria of sanitary vessels, please read "Guide to Sanitary Design for Custom Vessels", a quick-read guide to sanitary standards, construction and the effects on delivery and cost.

Apache Stainless Equipment Corporation is a manufacturer of stainless equipment for a range of hygienic industries, including, food, beverage, biotechnology, pharmaceutical, cannabinoid, and life sciences.

A dedicated quality control and compliance team directs all tests, certificates and documents for all sanitary, ASME, and global standards.

ASME Hygienic Vessel Construction Parameters

Tue, 18 May 2021 17:39:15 GMT

ASME (American Society of Mechanical Engineers) is a leading developer of codes and standards in the mechanical engineering community. ASME code section VIII details mandatory rules regarding vessel design, including engineering, manufacturing, and testing of pressure vessels. These standards enhance public safety and health as well as promote quality and innovation. Here are the main parameters outlining ASME construction of pressure vessels with supporting ASME testing requirements.

Construction
Parameters such as wall thickness, material, and flange rating are determined by the application, including pressure, temperature, corrosion allowance, and fluid flow. These conditions are calculated and reviewed/approved by the ASME inspector when required per code. Stainless, Hastelloy, AL6XN, duplex, and Inconel materials are ASME-approved materials for pressure vessel construction in the pharmaceutical, life sciences, and health-related industries, of which Apache is qualified to fabricate.

Welding
ASME standards also define the quality, type, and finishing of the welds. Head styles (ASME F&D, 80:10, 2:1 Elliptical), seams, nozzles, manways, and other components are designed per ASME Code. Applicable ASME Code welding procedures must be followed using certified ASME welders to maintain the structural integrity of an ASME pressure vessel. Welders must be certified to a qualified weld specification qualified per ASME code guidelines.

Safety Components
Gauges, valves, pressure outlets, and drainage are required safety components in ASME design pressure vessels. The proper selection of components and design is critically important to the safety and performance of the ASME vessel. The selection of safety components needs to be evaluated closely to define the required scope of supply.

Finishing
There is another ASME specification to ensure the quality and safety of parts used in pharmaceutical, bio-processing, and other industries requiring a hygienic vessel, called ASMP-BPE. BPE (Bio Processing Equipment Standard) specifies the surface finishes RA (roughness average) requirements and pickle passivation and electropolishing requirements.

Tests & Certification
There are significant testing, certifications, and documentation requirements for ASME compliance and satisfying the numerous customer requirements. Many require ASME inspection as well as a TOP (turnover packet). Some ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT.

Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.

5 Key Questions When Searching for New Cannabis Processing and Extraction Vessels

Thu, 22 Apr 2021 21:40:22 GMT

As the Cannabis Processing industry continues to evolve, increasing regulations are following. With continuous new products and additive combinations entering the market, the sale and distribution of the products will have more regulations. The processing and production of CBD and cannabidiol components are already seeing increasing standards.

When searching for a new Cannabis Processing or Extraction vessel equipment supplier, ask these five questions:

Does the vessel supplier have experience with the types of processing equipment you require to produce your product? The vessel manufacturer should have experience with CBD and Cannabis processing vessels, extraction tanks, mixing tanks and separating vessels. For complex applications or scale solutions, you may need to consult a process engineering firm to solve your CBD process challenges.
If you aren’t sure about the type of equipment you need, do you have access to collaborate with the vessel manufacturer’s application and engineering team to discuss your challenges? There continues to be numerous start-ups for new types of CBD products, and that equipment can come at a high cost. There may be value in a collaborative meeting with application specialists to vet your project and costs and learn more about equipment offerings.
What types of processes and components does the vessel manufacturer offer for the hygienic design? The FDA and other regulatory agencies will set the standard for sanitation and hygienic design in the CBD / Cannabis processing industry. Your vessel manufacturer must have offerings and experience with COP (clean out-of-place) sanitation and CIP (clean-in-place) sanitation components. They must also meet RA (roughness average) requirements and offer mechanical and chemical finishing services to meet the hygienic requirements set by regulatory agencies.
Does the vessel manufacture hold ASME certification? Most local and state laws require vessels designed at 15 PSI and higher to be ASME certified. Moreover, ASME requirements are also in material specifications, construction, and welding qualifications. Determine all industry compliance accreditations, including FDA, 3-A, CRN, PED and BPE.
Does the vessel manufacturer provide the testing and documentation services you need for your Cannabis or CBD processing vessel? There are significant testing, certifications, and documents requirements for all US and global accreditation programs. An experienced quality assurance department will provide trained and certified personnel; and assure the proper procedures and documentation to support your vessel.

Apache Stainless is a manufacturer of sanitary, highly engineered, ASME pressure vessels for a multitude of industries, including cannabis processing, pharmaceutical, health and biopharma. We have served the Cannabis and CBD processing industry several years with processing tanks, hydrocarbon extraction tanks, mixing tanks and separating vessels. We also design and manufacture vessels with Canadian Registration Numbers (CRN) for all Canadian provinces. We have all Stainless ASME certified manufacturing facility with custom capabilities including heat exchange surfaces, agitation, CIP (clean-in-place) componentry and controls. Apache has an in-house quality and compliance team to provide all testing and documentation requirements.

Visit Small Vessels for more information.

How to Evaluate a Custom Pressure Vessel Manufacturing Partner

Mon, 29 Mar 2021 22:13:44 GMT

Accreditations

Custom and pressure vessel manufacturers must have accreditation for ASME certification. Compliance with the National Board of Boiler and Pressure Vessel code is required. Pressure vessel manufacturers must also manufacture to ASME material specifications, certificates, and welding qualifications.

Other accreditations are also crucial in the pharmaceutical, life science, and health industries. Confirm all industry compliance standards, including:
•   ASME UM
•   ASME U
•   FDA
•   3-A
•   CRN
•   PED
•   BPE

Quality Assurance & Compliance

Verify that the manufacturer has a dedicated quality assurance team. There are significant testing, certifications, and documentation requirements for all global accreditation programs. In-house inspection services are a benefit to ASME projects. Review services that should include:
•   Pneumatic testing
•   Hydrostatic testing
•   Liquid Penetrant (Dye Penetrant) testing
•   Saline testing and certificate
•   Riboflavin/CIP (clean-in-place) coverage test
•   Material Test Reports
•   Base metal thickness certificate
•   Material trace
•   Welder trace
•   Ferroxyl test and certificate
•   Positive material identification (PMI) and certificate
•   Ferrite levels and certificate
•   Radiography and analysis
•   UT weld testing and certificate
•   Turn Over Packet (TOP) as required

Experience

The pressure vessel manufacturer must have expertise in the type of vessel and industry experience for the use of the vessel. Critical staff, fabricators, and welders must be ASME certified. All welders must be approved for the weld procedures required to make custom pressure vessels.

Experience and reputation are also significant when developing relationships with inspectors, agencies, and governing officials to keep the compliance process moving forward smoothly.

Service & Support

Above all, assess the service and support provided by the manufacturer. The vessel manufacturer should be able to articulate technical discussions and be open and honest with timelines, cost, and compliance-related issues. Consider other research and questions, such as:

•   Is the proposal easy to understand and compare solutions?
•   Do you have direct access to the engineer for questions?
•   Does the company provide timely and accurate documentation?
•   Does the company offer after-market parts and field service?

Download Small Vessel brochure
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How to Troubleshoot a Pressure Tank

Mon, 22 Mar 2021 19:42:35 GMT

There are several reasons why a vessel may need service, however, two main causes why a vessel may need service are either accident or performance related.

In the case of an accident, such as a tool falling into the tank and causing damage; surface scratches and dents can typically be repaired on-site, provided they do not go beyond minimum requirements, with mechanical polishing or hand/wand electropolishing.

Reduced agitator performance or failure is often due to worn parts, improper assembly or a bent or broken shaft. Agitator repairs may be addressed with the agitator manufacturer or the vessel manufacturer, depending on the situation, down-time, and severity of the failure.

When troubleshooting a drop in pressure in a tank or vessel, a typical cause is often related to seals. One sign of seal failure is product coming out of the seal. To help reduce the frequency of an unexpected seal leak occurring, it is recommended to use a good seal maintenance program to solve a lot of pressure / performance issues, such as:
•   Seal replacement has been neglected
•   Flat spots on seals are a sign for replacement
•   Improper or incorrect seals for the outlet
•   Nicks, scratches or mishandling of seals

A best practice is to avoid product waste and critical down-time is to inventory seals for all outlets and manage seals in a preventative maintenance program.

It is important to note that any weld repairs to the ASME pressures zones on tanks, require an R-Stamp. The R-Stamp is a certification required by the National Board of Boiler and Pressure Vessels for repair of an ASME tank or vessel.

Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide services including:
•   Field service and troubleshooting to all types of stainless and high alloy tanks
•   ASME / National Board R-Stamp repair and modifications
•   Surface finish repairs
•   Non-code repairs and modifications including piping and heat transfer jackets
•   Seal and agitation repairs and modifications
•   Accessory repairs
•   Head and tank shell repairs
•   Leak detection
•   Audit and service contract available

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General Use VS Custom Vessel: When It's Time to Consider a Custom ASME Pressure Vessel

Mon, 22 Feb 2021 16:11:20 GMT

Emerging life sciences, and health and wellness product manufacturers must carefully plan budget and start-up costs to launch their products. Many of these entrepreneurs begin production with a general use vessel.

A stainless general use vessel has a lower entry price. Depending on the process and the demand for the product, general-use vessels may serve a small manufacturer very well for many years. Dispensing and storage vessels, vacuum, and low-pressure vessels are common examples of general use applications.

However, when demand outpaces production, the manufacturer may require a vessel that is customized for the processing needs. Here is a case story of a manufacturer that switched from a general use to a custom ASME pressure vessel:

BEFORE: A fast-growing botanical extraction processor was unable to produce the quantity of product needed to fulfill demand. Their process involved an imported general use vessel that was placed in a rudimentary ice bath for temperature control. This process resulted in waste of non-consistent product, constant staffing, and manual intervention to monitor and adjust.

AFTER: Apache's small vessel team provided an ASME processing vessel that completely replaced their batch process. The new vessel was designed with a thermal heat jacket that heated and cooled the product to the exact temperature required for the extraction process. The ASME vessel was jacketed with tri-clamp ferrules and included a site glass and high-pressure sanitary fittings. The vessel has a pickle passivated finish that provides ease of sanitation between batches.

While the price point for a custom manufactured vessel was higher than a general use tank, the ability to quadruple production off-set the cost of the vessel and resulted in a quick return on investment. Apache's custom vessel runs continuously day and night; it eliminated product waste and removed employee monitoring and intervention.

Visit standard vessels or visit custom ASME vessels for more information!

What is the Significance of Domestic and Foreign Stainless Steel for Original Commercial Equipment?

Wed, 17 Feb 2021 12:47:41 GMT

The steel material used in manufacturing commercial original equipment must fit the performance, pricing, delivery time, and quality requirements for the end-user. Industrial equipment suppliers, like Apache, must leverage relationships with mills and partnering suppliers to manage the constantly changing market. Part of the purchasing program for the stainless material program at Apache, focuses on partnering with quality domestic and foreign suppliers.

Stainless sheet and plate are produced in the United States, which is the majority of Apache’s base material for tanks, vessels and food processing equipment. Also, most Hastelloy and other high-alloy performance metal materials are made in the US. Pipes and fittings on the other hand are primarily from foreign suppliers since domestically there is not enough availability for demand.

Depending on the political climate, import tariffs affect the cost and availability of steel material from China and other countries. Some industries require products from foreign markets that may be a specific sheet, size, and material type, but those industries will pay a premium for it and may be subjected to extended delivery times.

One of the benefits to being a significant user of stainless steel is the relationships with stainless producers and distributors. Apache’s steel venders allocate an allotment of material to Apache, which affords relatively short transactions for supply. When we have a line on repetitive need, we initiate inventory strategies to keep our supply as fluid as possible. Many other components and materials are affected by timing and supply; Apache understands lead times and availability and also leverages relationships to manage delivery to provide the best timing possible.

Our suppliers understand our needs and hold a higher level of steel quality. The relationship and partnership with our steel vendors has strengthened our expectations, with some partnerships lasting up to 45 years when Apache was founded.

Apache uses more than 2000 tons of stainless and high alloy per year. We are in the business of heavy gauge commercial manufacturing of custom equipment for high-compliance industries. Our ability to manage domestic and foreign material as well as price, timing and quality of all material and components is resolved for serving over 100 industries represented by our industrial and commercial processing customers.

A Comprehensive Read on Heat Transfer Surfaces

Tue, 21 Jul 2020 21:28:00 GMT

To help inform our tank and vessel customers about jacketed vessels and heat exchange surfaces, Apache shares this e-book that in-house specialists produced, "Abstract and Attributes of ASME Vessel Heat Transfer Surfaces".

Jacketed vessels are used in many industries and can remove the elevated heat of reaction (heat reactor vessel) or reduce the viscosity of high viscous fluids. There are basically three types of external jacketed heat transfer surfaces: conventional jacket, half pipe jacket and dimple jacket, which are welded to the outside of the vessel. Internal coils can also be used as a stand alone option or in combination with other types of external jackets.

Complimentary Download

Custom Vessels for Extreme Compliance Industries

Mon, 01 Apr 2019 21:11:48 GMT

The Small / Portable Vessel group produces specialized ASME vessels that customers need for their extremely regulated processes. Apache manufactures custom mix tanks, storage tanks, jacketed vessels, heat exchange surfaces, extraction equipment.

The Apache Stainless Equipment Corporation employs experts and artisans in the fabrication of stainless equipment for a range of industries. Our expertise in stainless and high-alloy vessels is shown on Apache's tanks and vessels in the beverage, biotechnology, life science, pharmaceutical, and food processing industries.

Apache offers engineering and 3D modeling to the customer's design conditions and ASME requirements for each vessel project. We have a dedicated quality and compliance team that focuses on verification, testing, and compliance documentation.

In addition to ASME, Apache is also accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our equipment products.

Download the custom story of Apache's Small Vessel Group.

New E-Book: Factory Tests and ASME Certifications Explained

Tue, 06 Mar 2018 19:13:00 GMT

An important part of quality assurance is the process of manufacturing a vessel and the completion of required certifications to meet ASME compliance. Equally important is the understanding of these processes and procedures, by all parties from project engineering manager to purchasing teams.

Apache's quality experts have put together a informative resource on factory tests and certifications for ASME tanks and vessels. It is important to have an understanding with customers about what is involved with testing and documentation requirements.

Highlights include:

A review of factory tests
Manufacturing process that require reporting
An overview of certifications
The TOP (Turn Over Packet) Documentation Package

DOWNLOAD EBOOK

Two Local Companies Work Together to Solve Need for Increased Production and Storage

Tue, 10 Jan 2017 21:32:10 GMT

Brakebush Brothers, a leading processor of chicken products, worked with Apache Stainless Equipment Corporation to design, fabricate and deliver a new 20,000 gallon fresh oil tank for their Westfield, Wisconsin plant.

David Meyer, Utilities Manager at Brakebush, needed a new storage tank to keep up with production demands and chose Apache Stainless for it’s reputation as a quality manufacturer of stainless tanks and expertise in heat transfer surfaces and sanitary tank finishing. The 13’ 6” diameter tank is 33’ feet tall and replaces an 8,000 gallon tank that will be relocated to another Brakebush plant.

David Foulkes, Sales Manager for Apache, worked with Brakebush and Apache’s tank team to provide the new tank with specifications to include a containment shell, steam dimple jacket, insulation and protective shroud with controls to monitor and adjust the heat temperature of the oil, especially during the winter months in Wisconsin, as well as the required flow into the plant for production operations.

The Brakebush Westfield, Wisconsin plant has a production facility of over 500,000 sq. ft. with state of the art cooking operations. Westfield is also the corporate office for Brakebush.

Apache Stainless located in Beaver Dam, Wisconsin serves commercial manufacturers all across North America. Apache tanks are found in food and beverage processing facilities an in fuel refineries, ethanol plants, chemical industries, biotechnology and pharmaceutical companies and in health and beauty product manufacturing plants.

What is the difference between pickle passivation and electropolishing?

Tue, 05 May 2015 19:10:00 GMT

The main difference between pickle passivation and electropolishing is the appearance and RA (roughness average) of the stainless material. In the photo, an electropolished sample is shown above a pickle passivated sample. The pickle passivated sample has a white appearance, while the electropolished sample has a mirror-like, shiny finish.

Pickle Passivation is the immersion of metal in a pickling bath such as nitric-hydroflouric acid. The process removes metal such as impurities and heat marks from welds.

Electropolishing is an electro-chemical process that removes surface material from stainless steel. The process typically starts with an immersion of the component into a controlled bath of electrolyte that is charged with a DC power supply. Apache’s RA tests show improvements up to 50% smoother, depending on the material.

Do you have more questions like this one?

Check out the Contract Manufacturing FAQs page.