Real plants. Real results.
Every engagement is different — different plants, different problems, different solutions. What's consistent is the outcome: measurable improvement in plant performance. Here are some examples of what we've delivered.
Pasteuriser throughput increased 18% through control loop optimisation
Challenge
A dairy processing facility was running their pasteuriser at 82% of design capacity. The plant had been commissioned 18 months prior and operators had accepted the conservative control settings as 'how the plant runs'.
Approach
SDA conducted a full control loop audit across the pasteuriser and associated CIP circuits. We identified 14 PID loops operating with excessive integral action causing oscillation, and three cascade loops that had never been properly tuned.
Outcome
Following retuning and control narrative revision, the pasteuriser achieved 97% of design throughput — an 18% improvement. Product quality variability also reduced by 40% as measured by out-of-spec batch rate.
+18%
Throughput increase
−40%
Quality variability
6 weeks
Implementation time
CIP programme redesign reduced water consumption by 30% and cycle time by 25%
Challenge
A beverage manufacturer was experiencing excessive CIP cycle times that were limiting production availability. Water and chemical costs were also significantly above industry benchmarks.
Approach
SDA performed a detailed CIP programme review including conductivity profiling, temperature mapping, and flow velocity analysis across all circuits. We identified oversized pre-rinse volumes, incorrect chemical concentrations, and inefficient recovery sequencing.
Outcome
Redesigned CIP programmes reduced total cycle time by 25%, freeing up an additional 2 hours of production time per day. Water consumption dropped 30% and chemical costs reduced by 22%.
−25%
CIP cycle time
−30%
Water consumption
+2 hrs
Daily production time
Centrifuge vibration resolved — eliminating unplanned shutdowns and restoring design capacity
Challenge
A food processing facility was experiencing recurring unplanned shutdowns on a critical centrifuge due to high vibration trips. The issue had persisted since commissioning and had been attributed to product variability by the OEM.
Approach
SDA conducted a vibration analysis and mechanical inspection that identified a combination of rotor imbalance and a resonant frequency in the support structure that coincided with the operating speed range. The OEM's diagnosis was incorrect.
Outcome
Following rotor rebalancing and a structural modification to detune the support frame, the centrifuge has operated without a vibration trip for 14 months. Design capacity has been fully restored.
0
Vibration trips in 14 months
100%
Design capacity restored
−85%
Maintenance cost reduction
Project details have been generalised to protect client confidentiality. Specific metrics are representative of actual outcomes achieved.
Want results like these for your plant?
Every plant is different, but underperformance always has a root cause. Book a consultation and let's find yours.