Creating nonwoven fabrics requires using roller cards to process staple fibre, with the rollers first warmed using steam. With boilers operating to create this steam 24 hours a day, boiler maintenance is a critical element of nonwoven local manufacturer Fibertex South Africa’s operations.

Key to Fibertex are the automotive, bedding, filtration, furniture and geotextiles business areas. Fibertex works with leading South African boiler manufacturer Allmech to maintain and protect its boilers.

The nonwoven manufacturer contacted Allmech in 2009, ahead of setting up its factory, to enquire about the supply of an electrode boiler capable of supplying 470 kg/h steam. Allmech’s KwaZulu-Natal branch manager Arno Pieters explains that the Allmech team recommended an AHP-300P electrode boiler with a duplex water softener because Fibertex operates 24 hours a day.

In 2018, Fibertex required another boiler for its raw material plant, Fiberline. Allmech supplied a second electrode boiler of 100 kW (AA-100) to replace a non-Allmech unit, which was troubling Fibertex.

“Allmech electrode boilers operate on the principle that electricity passed through any resistant material causes an increase in that resistant material’s temperature,” says Pieters, noting that in this instance, the resistant material is water.

The use of this principle ensures no external heating mechanism is required and it renders the boiler safe under all operating conditions. “In other words: no water, no resistant material and no increase in temperature,” adds Pieters.

Allmech was founded in 1995 and has grown over two decades to become one of South Africa’s leading boiler manufacturers and water treatment industry suppliers.

Boiler water treatment is critical to ensure that the machinery functions correctly for as long as possible. Effective boiler feed water treatment systems work by both removing harmful impurities prior to entering the boiler as well as controlling the acidity and conductivity of the water.

“When impurities exist in the boiler water, they can foul the system and create lasting damage that will shorten the life of the equipment and reduce its efficacy, which translates to higher bills for the same performance,” says Pieters.

Allmech’s water treatment equipment was introduced through two operating principles. The first is water filtration by means of water softening, which reduces the amount of calcium and magnesium scale that enter the boiler. Scale directly impacts on the energy requirement of the boiler. Just 1 mm of scale increases electricity demand by 10%.

“The second operating principle is chemical treatment. Our Allmech A-101 electrode boiler solution contains oxygen scavengers, polyacrylate dispersants and scale inhibitors to ensure the boiler is kept clean,” adds Pieters.

Fibertex maintenance supervisor Victor Joubert says the relationship with Allmech has endured for 14 years thanks to the “excellent level of service” Allmech is able to provide. “If I have any problems, I can call [Pieters] and he will help,” Joubert says.

He lauds the fact the he is working with a “one-stop shop”, adding that he is able to buy the water treatment chemicals from Allmech directly, and commenting on Allmech’s undertaking monthly water testing and regular monitoring and inspections of the boilers so that it can adjust treatment or provide maintenance as required.

“They help us to ensure we get the full [operational life] out of the boilers,” Joubert says, adding that Allmech finds solutions to ensure that hard water and chemical composition are not hinderances.

For example, as a result of changes in the water quality and an increased rust detection in the internals of the rollers, Allmech developed its A103 electrode boiler solution, which offers additional condensate protection properties.

“South African regulations require that vessels and boilers or steam generators are inspected and tested at prescribed intervals. Boilers and vessels require inspection every three years. “During the past 14 years, our Fibertex inspections have indicated no internal corrosion, which is the result we want to see,” concludes Pieters.