Client Challenge
A local brewery faced an urgent production halt on their canning line due to a CO2 pressure fault. The fault occurred mid-process, risking significant product loss and operational downtime.
The root cause of the issue was unclear, and our client required immediate assistance from our Field Services Team to diagnose and resolve the problem to prevent further disruption.
Our Solution
Our Field Services Team responded promptly to the emergency service call, deploying an experienced field service engineer immediately to address the issue.
The troubleshooting and resolution process included:
- Fault Diagnosis: We conducted an in-depth analysis of the CO2 pressure fault and identified that the program was erroneously combining two setpoints regardless of production activity.
- Sensor Adjustments:
- It was determined that several proximity sensors on the line were misaligned.
- We were able to make precise adjustments to realign the sensors and ensure proper operation.
- Testing and Validation:
- Our field services team tested the production sequence multiple times after clearing the alarm to confirm that the fault was resolved.
- We verified the canning line’s functionality under normal production conditions.
- Client Collaboration: We consulted with the brewery’s management team to explain the modifications and ensure confidence in the system’s reliability before resuming production.
The Results
DSI’s rapid response and expert troubleshooting ensured the brewery’s canning line returned to full operation without any product loss:
- Production Resumption: The canning line resumed normal operation promptly, avoiding downtime-related financial losses.
- Issue Resolution: Adjustments to the misaligned proximity sensors and program corrections resolved the CO2 pressure fault effectively.
- Prevention of Product Loss: The quick intervention prevented any loss of product, safeguarding the client’s bottom line.
- Client Satisfaction: DSI’s responsiveness and clear communication reassured the client of their system’s reliability and our commitment to their operational success.
This project exhibits DSI Innovations’ expertise in emergency troubleshooting and rapid problem resolution, helping clients maintain productivity and minimize disruptions in critical situations.
