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Context
A food ingredient manufacturer had been reporting unexplained product staining and occasional contamination concerns within their bag filter system. Routine cleaning cycles and visual inspections had repeatedly failed to identify the source of the problem, leaving the quality team without a clear answer and the issue continuing to affect production.
The contamination risk was not only a product quality concern. It pointed to a deeper structural issue within the equipment that standard inspection methods were simply not equipped to uncover.
Challenges
We were contracted to carry out a thorough bag filter system inspection covering internal bag filter housings, product-contact welds, duct transitions, and powder accumulation zones. The main issue was finding defects hidden by compacted powder deposits. These defects had been missed during previous cleanings and visual checks.
Uncover hidden defects in your bag filter system with Bioscan’s NDT inspection.
The Bioscan Response
Bioscan mobilised a team to conduct a detailed internal inspection of the bag filter system. Our baghouse filter testing revealed hidden corrosion beneath compacted powder deposits, surface degradation in moisture-prone areas, and localised pitting and cracking across multiple product-contact zones. These were not surface-level issues. The affected areas had created ideal conditions for product retention, bacterial harbourage, and cleaning shadow zones that routine methods could not reach or detect.
As a specialist industrial inspection company, we understand that what is visible during routine checks rarely tells the full story, particularly in powder-handling systems where build-up can conceal significant structural and hygienic risk over time.
After finding issues, we removed damaged materials, fixed the stainless steel parts, and polished the surfaces that touch the product. Once we finished, we did a baghouse integrity test to make sure everything met the hygiene standards. The system then went back online, good as new.
Outcome
After our inspection, we took out all the worn-out materials and fixed the damaged stainless steel parts, then polished the product contact surfaces. We ran a baghouse integrity test afterwards to ensure everything met the needed standards before putting the system back into use.
Protect your food facility from hidden contamination risks with specialist inspections.
Impact
This case shows that food processing problems often stem from issues that visual checks can’t catch. Bioscan’s bag filter inspection helped the manufacturer fix a longstanding problem by giving them clear insights. They were able to take corrective actions, improving their hygiene in the long run.
Your next inspection could uncover what routine checks have been missing. Get in touch with Bioscan to discuss a tailored inspection programme for your facility.
