Solving pasteurization issues: A customer success story

In the world of food and beverage production, meeting the highest quality and safety standards is of paramount importance. Pasteurization, a key process in ensuring product safety and shelf life, can sometimes be challenging. In this article, we will look at a real-life case where a customer faced pasteurization issues with their equipment and how they successfully resolved the issue with the help of monitoring systems and experienced process engineers.

Tasks:

Our client, a beverage manufacturer, was facing a significant problem with its pasteurizer. Although it had previously been operating at the required pasteurization level of 300 pasteurization units (PU), the equipment was no longer reaching the desired level. This discrepancy was a cause for concern as it directly affected the microbiological safety and shelf life of the product.

Solution:

To solve the problem, the client turned to Viravix Engineering and its experienced director, Yuriy Fedyay. Yuriy and his team used the QiVisor monitoring system, which allowed them to analyze the pasteurization process in detail and identify the root cause of the problem.

With the help of the monitoring system, Yuriy discovered that the pasteurizer was initially set up for 50 PUs, which are designed to pasteurize beer, instead of the required 300 PUs for lemonade. This incorrect setting led to unstable operation of the pasteurizer and a subsequent drop in pressure and flow, which resulted in overheating of the product.

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

Advantages of monitoring systems:

The successful solution to the pasteurization problem was largely made possible by the introduction of the QiVisor monitoring system. This advanced IoT tool enabled real-time data collection and analysis, providing valuable insights into the pasteurization process. With QiVisor, the client was able to monitor important parameters such as pressure, level, density, temperature, and others, ensuring the smooth operation of their pasteurization plant.

The monitoring system not only helped to quickly identify the error, but also offered a number of other benefits. It allowed the process engineer to analyze the data remotely, thus eliminating the need to visit the plant. In addition, the system provided alerts and warnings about any deviations from the desired parameters, allowing for immediate corrective action.

Lessons learned and future optimization:

The customer’s experience serves as a valuable lesson for other food and beverage manufacturers. Implementing a reliable monitoring system such as QiVisor can significantly improve process efficiency, reduce product waste, and ensure compliance with industry standards.

In addition, this case study emphasizes 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 solution to our client’s pasteurization problem demonstrates the significant impact of monitoring systems and experienced process engineers in the food industry. With advanced technology and expert knowledge, companies can overcome challenges, optimize their processes, and deliver safe, high-quality products to consumers.

If you are a food and beverage manufacturer facing pasteurization challenges, don’t hesitate to seek professional help and consider implementing a reliable monitoring system. This way, you can protect your brand reputation, ensure product safety, and optimize your operations for long-term success.