Real Pet Food — Yatala
How a controlled acid clean of a silica-scaled 6 MW boiler saved a Queensland pet food manufacturer approximately $45,000 per month and returned the plant to full steam independence on a single boiler.
The Challenge
A 6 MW steam boiler at the Yatala facility was producing only 4,800 kg/hr against a rated output of 9,100 kg/hr, forcing the site to run an auxiliary 4 MW boiler simultaneously to meet production demand. O'Brien identified excessive silica scale deposits within the tube bundles as the cause. Over 18 months, O'Brien and the site's water treatment provider progressed a careful online descaling program, but stubborn high-silica deposits remained and required a specialist chemical response.
On site — before and after
The Solution
O'Brien developed a staged plan to restore boiler performance while keeping the site operational. A 1.25 MW rental boiler was installed alongside the auxiliary 4 MW boiler to maintain production while the 6 MW unit was taken offline. O'Brien then completed a controlled acid clean using inhibited hydrofluoric acid, selected for its effectiveness against high-silica scale and carefully managed to protect the boiler metal and preserve the long-term condition of the asset.
The Outcome
Following the works, the 6 MW boiler now operates the plant independently, eliminating the need for the auxiliary 4 MW unit. Real Pet Food reported a 28.5 per cent reduction in gas consumption, representing an estimated saving of approximately $45,000 per month. The result reflects the value of a technically controlled, patient approach to boiler performance recovery delivered end-to-end by a single partner.