Case Study

Overview

A multi-national dairy manufacturer relied on a robotic visual inspections for 3 consecutive years. Each inspection reported zero cracks inside the spray dryer, and the equipment was considered conformed.

In 2024, after hygiene deviations and rising micro counts, the manufacturer requested a full inspection from Bioscan using it’s advanced electronic crack detection. Bioscan identified more than 50 cracks and defects in a single visit.

Robotic Visual Inspections (Years 1–3)

• HD visual robotic camera
• Limited access in complex geometries
• Limitied detection capability for micro-cracks or weld fatigue
• 0 defects reported each year

Bioscan Inspection (Year 4)

• Electromagnetic crack detection
• Access platform and rope-access methods ensuring full surface coverage
• 50+ cracks discovered, including:
  • Weld cracks
  • Fatigue cracks
  • HAZ cracking
  • Through-wall defects
  • High-risk cracks near nozzles, bustle, duct transitions

Impact on the Client

1. Major Unplanned Shutdown

The extent of damage required a two-week emergency shutdown, halting production immediately.

2. Direct Financial Costs

• $200,000 – welding repairs, polishing, labour and specialist access
• $950,000 – production losses from unplanned downtime
• Total: $1,150,000 impact from issues that went undetected for three years

3. Contamination and Compliance Risk

Because cracks had been present for multiple years, the site faced:

• Hidden microbial harbourage
• Reduced cleaning effectiveness
• Compromised hygiene during audits
• Increased product quality risk

The visual inspection “all clear” created a false sense of security.

Root Cause of Missed Defects

• Robot could not access or illuminate critical weld zones
• Surface glare and product residue concealed cracks
• Technology limited to visual inspection — no crack detection
• No detection of early-stage or sub-surface defects

Outcome

• Dryer restored to full hygienic condition after repair
• Structural integrity re-established
• Robotic inspections discontinued
• Bioscan adopted as the annual inspection standard across the site

Conclusion

This case highlights the risks of relying solely on robotic visual inspection. Over 50 cracks developed undetected, resulting in:

• Serious food-safety exposure
• A two-week shutdown
• $1,150,000 in unexpected costs

Bioscan’s technology provided the accuracy and depth needed to prevent future failures and
protect production integrity.

Context

A major dairy products manufacturer in the Netherlands encountered a grave concern when abnormal microbes were detected in a sample from their largest spray dryers. Fearing the possibility of contamination spreading through their products, the company quickly mobilised to address the issue. With the risk of an operational halt on the horizon, the company faced a critical moment that required decisive action to mitigate the potential impact on their business operations.

Challenges

We were called in on a tight deadline to identify the root cause of abnormalities found in the samples. Our task was to perform a full internal scan of the spray dryer and carry out all necessary repairs within 24 hours of the call.

The Bioscan Response

Bioscan’s emergency rapid crack detection team was deployed on the site. We performed a full internal scan of the spray dryer to detect and repair any cracks, minimise downtime, and ensure food safety compliance.

Outcome

We detected multiple micro-cracks through our micro-crack detection methods near the weld seams, which were not visible to the naked eye. Bioscan, a leading provider of inspection services, carried out localised repairs during the shutdown window and resumed production within 24 hours. With our highly effective crack detection services, we helped the dairy plant avoid significant costs, estimated at over 1 million Euros in downtime and lost output. We were praised for completing the dairy plant inspection through crack inspection services within 18 hours of arrival. 

Impact

This case underscores the power of real-time, accurate defect detection through nondestructive testing. Without Bioscan’s rapid spray dryer inspection, they could have faced the risk of contamination and massive financial and operational losses. Instead, they transformed an emergency into a successful mitigation story.

If you are looking for an effective and rapid-response-equipped industrial inspection company, look no further than Bioscan. Our industrial inspection services are designed to carry out any emergency industrial inspections within tight deadlines. Contact us today; we are just a call away!

Context

A leading US-based infant formula manufacturer reached out to Bioscan to conduct a comprehensive spray drying inspection. Their goals were to ensure that every component of the spray dryer (which transforms liquid concentrate into powder formula) system meets the strictest hygiene and safety standards. 

Challenges

The request was to detect early signs of cracking, maintain full compliance, and perform repairs with a tight 48-hour shutdown window. In short, we had to perform a full inspection and repair of the spray dryer system during the scheduled shutdown through our non-destructive inspection technology. 

How We Approached the Challenges

Bioscan mobilised a team to the site, using our proprietary non-destructive electronic inspection methods to initiate testing. With IRATA-certified rope access, we inspected the entire spray dryer chamber and cone, fluid bed, ducting system, and cyclones, without the need for scaffolding, then performed the welding repairs.

Outcome 

Upon thorough food industry equipment inspection, we identified some potentially vulnerable non-visible cracks and biofilm-prone areas and addressed them on the spot. With the help of our highly skilled technicians, we completed the entire inspection and repaired cracks within the deadline. We also delivered a comprehensive report, covering every issue we had identified during the inspection and repair for future maintenance planning.

Impact

The client gained accurate insight into asset health, minimised risks of contamination, and avoided emergency downtime. The inspection supported global compliance and helped the team build a predictive maintenance strategy, demonstrating the efficacy of our vessel crack test inspection services. 

This case study is a testament to our expertise in real-time nutritional food processing equipment inspection. We rigorously strive to ensure every inspection is carried out with the highest level of accuracy, leaving no defect undetected. Our precision in spray dryer crack inspection helps clients avoid unexpected shutdowns, supports audit readiness, and keeps costs and disruptions to a minimum.

If you are ready to have your spray dryer system inspected through our high-quality and effective spray dryer inspection services, contact us today. We are just a call away!