CASE STUDY
Thermal Process Optimization and Stability Audit
Beverage Bottler
Beverage Manufacturing / Bottling
On-site thermal process audit; PID loop tuning and process control adjustments; PLC and HMI modifications; Equipment troubleshooting and tuning; System instrumentation recommendations; Standard Work Instructions and training guidance
Overview
TM Process & Controls, Inc. conducted a multi-day audit at a bottling facility to support the optimization of Line 4. The primary focus was to resolve persistent issues with fluctuating pasteurization temperatures and flow rates that were outside specification, impacting process consistency and product quality.
Problem
The bottling line experienced unstable process flow and temperature values, causing pasteurization inconsistencies. PID loop settings had drifted, valves and pumps were underperforming or mismatched, and system-level issues like manual mode overrides and tank cavitation were introducing process instability. Safety risks and equipment wear were also flagged due to poor thermal system control.
Solution
TMPC reverted PID tuning to validated baseline settings, implemented new control logic for modulating valve behavior, and added instrumentation to stabilize flow. Mechanical upgrades were made during production, including installing a new valve positioner and adding pressure/flow instrumentation. TMPC also recommended system design changes and created plans for comprehensive training and Standard Work Instructions to improve long-term operability and safety.
Results
- Significant improvement in flow and temperature stability
- Faster PID response and reduced flow fluctuations
- Process adjustments completed live during production
- Identified mechanical deficiencies with actionable recommendations
- Enhanced system reliability and foundation laid for operational best practices
