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Solving Pasteurization Issues

Solving Pasteurization Issues: A Client's Success Story

In the world of food and beverage production, maintaining the highest quality and safety standards is of paramount importance. Pasteurization, a key process in ensuring product safety and shelf life, can sometimes present challenges. In this blog post, we will explore a real-life case study where a client faced pasteurization issues with their equipment and how they successfully resolved the problem with the help of monitoring systems and experienced process engineers.

The Challenge:

Our client, a beverage manufacturer, encountered a significant issue with their pasteurizer. Despite previously operating at the required pasteurization levels of 300 Pasteurization Units (PU), the equipment was no longer reaching the desired level. This discrepancy raised concerns as it directly affected the product's microbiological safety and shelf life.

The Solution:

To address the problem, the client sought the expertise of Viravix Engineering and their experienced director, Yuriy Fedyaj. Yuriy and his team utilized a monitoring system, QiVisor, which allowed them to analyze the pasteurization process in detail and identify the root cause of the issue.

Through the monitoring system, Yuriy discovered that the pasteurizer was initially set to 50 PU, intended for beer pasteurization, instead of the required 300 PU for lemonade. This incorrect setting led to unstable pasteurization units and a subsequent drop in pressure and flow, resulting in overheated product.

By quickly identifying the error, the team was able to rectify the situation promptly and prevent any further damage to the product. They promptly adjusted the pasteurization settings and restored the correct PU level.

The Benefits of Monitoring Systems:

The successful resolution of the pasteurization issue was largely attributed to the implementation of the QiVisor monitoring system. This advanced IoT tool allowed real-time data collection and analysis, providing valuable insights into the pasteurization process. With QiVisor, the client could monitor crucial parameters such as pressure, level, density, temperature, and more, ensuring the smooth operation of their pasteurization plant.

The monitoring system not only helped identify the error quickly but also offered several other benefits. It enabled the process engineer to remotely analyze data, thus eliminating the need for on-site visits. Additionally, the system provided notifications and alerts for any deviations from the desired parameters, allowing for immediate corrective actions.

Lessons Learned and Future Optimization:

The client's experience serves as a valuable lesson for other food and beverage manufacturers. Implementing a robust monitoring system, like QiVisor, can greatly enhance process efficiency, reduce product waste, and ensure compliance with industry standards.

Moreover, this case study highlights the importance of proper training and familiarization with equipment settings to prevent errors during production. By investing in employee training programs and continuous improvement, manufacturers can minimize the risk of similar issues in the future.

Conclusion:

The successful resolution of the pasteurization issue faced by our client demonstrates the significant impact of monitoring systems and experienced process engineers in the food and beverage industry. By leveraging advanced technologies and expert knowledge, companies can overcome challenges, optimize their processes, and deliver safe and high-quality products to consumers.

If you're a food and beverage manufacturer experiencing pasteurization problems, don't hesitate to seek professional assistance and consider implementing a reliable monitoring system. By doing so, you can protect your brand reputation, ensure product safety, and streamline your operations for long-term success.