Ultrasonic Testing for Food and Beverage Processing Plants

Ultrasonic Testing solutions tailored for Reliability Consulting for Food & Beverage Facilities operations.

47% Reduction in unplanned downtime
85% Faults detected before failure
3-6mo Average fault lead time
5:1 Typical program ROI

Why it matters

Key Benefits

Ultrasonic Testing for Food & Beverage Equipment Reliability

Our airborne and structure-borne ultrasonic detection program inspects sanitary pumps, mixers, homogenizers, fillers, refrigeration compressors, and packaging line drives to detect compressed air leaks, steam trap failures, bearing lubrication deficiencies, and partial discharge in switchgear. In food & beverage environments — sanitary processing with frequent washdown, CIP cycles, and temperature extremes between cooking and cold storage zones — sanitary design requirements prevent standard sensor mounting methods and require food-grade materials in the process zone. Our team delivers leak survey maps with estimated CFM losses and ROI calculations for repairs calibrated to the specific failure modes and operating conditions found in food & beverage operations.

Supporting FDA/FSMA Compliance Through Condition Data

Food & Beverage facilities operate under FDA 21 CFR Part 110/117, FSMA, HACCP, and SQF/BRC audit requirements. Our airborne and structure-borne ultrasonic detection program generates documented condition records that demonstrate haccp prerequisite program documentation proving equipment reliability supports food safety. This audit-ready documentation reduces regulatory exposure and supports your team during inspections and third-party audits.

Reducing Product Contamination in Food & Beverage

Unplanned equipment failures in food & beverage operations cause product contamination, batch holds, recalls, and audit non-conformances. Washdown exposure limits sensor installations; cip schedules restrict equipment access windows. By applying airborne and structure-borne ultrasonic detection to sanitary pumps and other critical assets, our program provides the advance warning needed to schedule repairs during available maintenance windows and protect production yield and food safety compliance rate targets.

Context

Challenge & Approach

The Reliability Challenge

Compressed air pressure drops from leaks affect packaging seal integrity and pneumatic valve response. Steam trap failures impact CIP and pasteurization temperature control. Surveys must work around sanitary production schedules. Food-grade compressed air systems require particular attention to leak locations near product contact zones.

Our Approach

We survey compressed air distribution from compressor room through production floor piping, quantify leak costs and prioritize repairs by savings magnitude, assess steam trap condition throughout the steam system, and identify any leaks near product contact zones that could affect compressed air system cleanliness classification.

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Common Questions

FAQ

Questions our clients ask most often about this reliability program.

In food & beverage operations, our airborne and structure-borne ultrasonic detection program focuses on sanitary pumps, mixers, homogenizers, fillers, refrigeration compressors, and packaging line drives. We measure high-frequency sound emissions from friction, turbulence, and electrical discharge to identify compressed air leaks, steam trap failures, bearing lubrication deficiencies, and partial discharge in switchgear before they progress to functional failure. Food & Beverage facilities present specific challenges: washdown exposure limits sensor installations; cip schedules restrict equipment access windows. Our program is designed around these constraints, delivering leak survey maps with estimated CFM losses and ROI calculations for repairs that your maintenance team can act on within the scheduling realities of food & beverage production.

Limited Availability
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Tell us about your equipment and facility. Our reliability team will review your situation and recommend a tailored reliability program — no obligation.

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Response within 1 business day
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No obligation. Typical response within 24 hours.

Survey Compressed Air and Steam Systems for Energy Waste

Compressed air leaks affect packaging seal quality and waste energy — we find and quantify every one.

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