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Context
A global infant nutrition manufacturer wanted to improve inspection consistency across multiple international spray dryer sites. Historically, each facility had been working with different contractors, reporting formats, and inspection frequencies, making it increasingly difficult to benchmark asset condition or manage hygienic risk in a reliable and uniform way.
The lack of standardisation meant that defect severity was being interpreted differently across locations, and there was no common framework to guide repair prioritisation or track asset health over time. The manufacturer needed a structured, long-term solution.
Challenges
We were brought in to design and deliver a unified nutrition manufacturing plant equipment inspection programme that could be applied consistently across all international sites. The scope covered spray dryers, cyclones, bag filters, fluid beds, and ducting systems. Beyond the inspection itself, the programme needed to include standardised defect classification, consistent reporting structures, repair prioritisation guidance, and the ability to track trends across facilities over time.
Standardise equipment inspection across your facilities with Bioscan’s expertise.
The Bioscan Response
Bioscan developed a standardised inspection programme and mobilised teams across the manufacturer’s global sites. Initial inspections carried out through industrial spray dryer testing identified significant variation between facilities, including undetected fatigue cracking, inconsistent repair quality, areas of recurring thermal stress, and differing interpretations of defect severity. What had appeared to be a managed asset base was, in reality, carrying a range of unresolved risks that had gone unquantified due to the absence of a unified approach.
Our spray dryer inspection methodology was applied uniformly across all sites, establishing a shared baseline for asset condition assessment. Industrial cyclone testing and bag filter crack testing were carried out as part of the same programme, ensuring full system coverage rather than isolated equipment checks.
We implemented unified inspection methodologies, risk-based repair classifications, global reporting templates, and a long-term defect monitoring framework to support ongoing asset management.
Outcome
The manufacturer gained greater visibility of asset condition across all sites, improved consistency in hygienic risk management, and a more reliable basis for shutdown planning. Confidence in the integrity of their production equipment increased measurably across the organisation.
Build a reliable long-term inspection programme with Bioscan’s specialist team.
Impact
This programme demonstrates the value of a coordinated, standards-driven approach to industrial equipment inspection across multi-site operations. When each facility operates in isolation, risk accumulates silently. Bioscan’s global programme replaced inconsistency with clarity, giving the manufacturer a repeatable, auditable framework for long-term asset integrity and industrial baghouse inspection management.
If you are looking to standardise inspection across your facilities, contact us today.
