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Context
A dairy processing facility had been experiencing recurring product build-up and inconsistent CIP (clean-in-place) results within its crystallisation system. Despite passing previous visual inspections, the quality team remained concerned due to intermittent microbiological deviations and repeated cleaning inefficiencies that continued to affect production reliability.
The crystallisation tanks had been subjected to years of temperature cycling along with agitation, which made them more vulnerable to fatigue cracking at their weld joints. Standard visual checks were no longer sufficient to provide the level of assurance the facility needed.
Challenges
The requirement was to inspect the crystallisation tank internally for walls, agitator supports, weld joints, outlet transitions, and any areas that come into contact with the product. The purpose of such an inspection was to pinpoint the underlying cause of microbiological and cleaning issues at the plant.
Detect hidden defects in your processing equipment with Bioscan’s NDT expertise.
The Bioscan Response
Our team deployed a combination of electronic crack detection, close-access visual assessment, and confined-space entry techniques to assess areas inaccessible through routine checks. The crystallisation tank defect investigation revealed multiple non-visible cracks around internal weld seams, high-stress outlet transitions, and agitator mounting points. Several areas also showed signs of product retention, surface degradation, and localised microbial harbourage risk. Each one of those problems had gone unnoticed during previous visual checks, but was nevertheless a cause of the inefficiency and microbial problems that the team was experiencing.
As a result of our findings, we conducted weld repairs, hygienic polishing, and verification of surfaces in all of the affected areas.
Outcome
The cleanability of the tank had improved considerably; product build-up incidents had reduced, and the hygienic credibility of the system was completely regained by the customer. Long-term inspection intervals were also implemented, making it possible for planned maintenance.
Protect your facility’s hygiene compliance with Bioscan’s specialist inspection services.
Impact
This case underscores the limitations of visual-only inspection in ageing dairy processing equipment. Without our non-destructive approach, the hidden defects would have continued to compromise food safety and cleaning compliance undetected. Bioscan’s dairy processing equipment inspection turned a persistent operational problem into a resolved and manageable maintenance programme.
If you are looking for reliable industrial equipment inspection services or need a specialist pressure vessel inspection for your facility, contact Bioscan today. We are just a call away.
