Food & Beverage
At DSI Innovations, we understand the unique demands of the Food and Beverage industry, where precision, safety, and efficiency are critical. In fact, we tackle our clients’ most difficult challenges head on! Our outstanding automation solutions include sanitary process control and recipe management systems to ensure product consistency and compliance with food safety standards.
From packaging and palletizing automation to advanced track and trace solutions, we’ll help you streamline production while maintaining full visibility across the supply chain. Our expertise extends to refrigeration and HVAC controls, as well as Clean-in-Place (CIP) systems, ensuring that your facility operates with maximum efficiency, hygiene, and uptime.
Our Food & Beverage Capabilities
Process Automation & Control
- PLC/HMI/SCADA Programming: Developing and integrating control logic, operator interfaces, and alarm management specific to F&B applications.
- Recipe & Batch Management (ISA S88): Automating recipes, scheduling, and ingredient handling for consistency in product formulation.
- Continuous Process Control: Optimizing flow control, temperature regulation, and real-time monitoring for smooth operation and product quality.
- Data Historian & Trending: Logging process parameters for quality assurance, traceability, and regulatory documentation.
- Advanced Process Control (APC): Employing predictive models or machine learning algorithms to enhance throughput and quality.
- Real-Time Monitoring & Alarms: Providing early detection of deviations or failures to minimize product loss and downtime.
Thermoforming & Extrusion
- Complete Extrusion Line Integration: Designing and implementing end-to-end extrusion processes, from raw material feeding to finished sheet or film output, ensuring consistent melt quality and throughput.
- Multi-Zone Heating & Forming: Utilizing precise, multi-zone PID controls and automated forming cycles to maintain uniform temperatures and achieve consistent product dimensions.
- In-Line Quality & Thickness Monitoring: Incorporating sensors, gauges, and vision systems to measure sheet thickness, detect defects, and generate real-time data for proactive adjustments.
- Automated Thermoforming & Trimming: Coordinating servo or pneumatic systems to streamline forming, trimming, and stacking operations, reducing cycle times and labor costs.
- Integrated Downstream Packaging: Linking formed packaging components—such as trays, cups, or lids—directly into filling, sealing, and labeling lines for a seamless operation.
- Advanced Process Control & Data Analytics: Deploying SCADA/HMI systems to gather real-time production metrics and employing predictive analytics to reduce downtime and improve efficiency.
Process Optimization & Upgrades: Conducting audits of legacy lines for targeted modernization, implementing updated controls, servo systems, and data logging to increase capacity and maintain product quality.
CIP/SIP & Sanitation Automation
- PLC/HMI/SCADA Programming: Developing and integrating control logic, operator interfaces, and alarm management specific to F&B applications.
- Recipe & Batch Management (ISA S88): Automating recipes, scheduling, and ingredient handling for consistency in product formulation.
- Continuous Process Control: Optimizing flow control, temperature regulation, and real-time monitoring for smooth operation and product quality.
- Data Historian & Trending: Logging process parameters for quality assurance, traceability, and regulatory documentation.
- Advanced Process Control (APC): Employing predictive models or machine learning algorithms to enhance throughput and quality.
- Real-Time Monitoring & Alarms: Providing early detection of deviations or failures to minimize product loss and downtime.
Packaging & Material Handling
- Filling & Sealing Systems: Programming and optimizing filling volumes, sealing conditions, and conveyor speeds to maintain product integrity.
- Labeling & Coding Integration: Synchronizing labelers, printers, and barcoding systems for accurate product identification and traceability.
- Robotic Palletizing & Case Packing: Utilizing robotics or automated pick-and-place solutions for efficient end-of-line operations.
- Automated Conveyors & Sortation: Controlling and coordinating conveyor lines, merges, and diverters to reduce bottlenecks.
- Vision Inspection & Quality Checks: Integrating cameras or sensors for label accuracy, seal integrity, and product defect detection.
Regulatory & Food Safety Compliance
- USDA, FDA, & FSMA Adherence: Ensuring control systems meet stringent food safety, labeling, and sanitation requirements.
- Traceability & Recall Readiness: Tracking raw materials and finished goods throughout the production cycle to enable rapid recalls if necessary.
- GFSI/BRC/IFS Alignment: Designing automation solutions that align with common global food safety standards.
- Electronic Records & Audit Trails: Maintaining secure logs of critical control points, quality checks, and product genealogy.
- Allergen Management: Implementing separate or automated cleaning protocols to prevent cross-contamination.
Instrumentation & Process Monitoring
- Sensor Selection & Calibration: Specifying and calibrating flow, temperature, level, pressure, and pH instruments for food-grade processes.
- Inline Quality Measurement: Integrating online analyzers (e.g., Brix, pH, turbidity) for continuous product quality feedback.
- Wireless & Remote Monitoring: Deploying wireless sensors to reduce wiring complexity and enable flexible plant layouts.
- Preventive Maintenance on Instruments: Scheduled calibration checks and replacements to sustain measurement accuracy.
- Robust Documentation & Certificates: Providing calibration reports and as-built drawings to support compliance requirements.
SCADA, MES & Data Integration
- Real-Time Production Tracking: Monitoring throughput, downtime events, and performance indicators at every stage of production.
- MES/ERP Connectivity: Integrating with higher-level systems for inventory management, production scheduling, and order processing.
- Batch Records & Reporting: Generating automated production records, including ingredient usage, batch times, and operator actions.
- OEE & KPI Dashboards: Displaying real-time plant performance metrics to empower data-driven decision-making.
- Traceability Database Systems: Storing granular product details for each batch or SKU to facilitate recall or quality investigations.
- Cybersecurity & Access Control: Protecting network integrity and sensitive data with secure firewalls, VPNs, and role-based user permissions.
Control Panel Design & Fabrication
- Food-Grade Enclosures: Using washdown-rated (IP/ NEMA) stainless steel panels for hygienic environments.
- UL/CE/CSA Compliance: Designing and labeling control panels in accordance with relevant electrical standards.
- Component Specification: Selecting PLCs, I/O modules, VFDs, and other hardware from reputable vendors suited for F&B applications.
- Wiring & Cable Management: Ensuring clearly labeled wiring, easy maintenance access, and minimal contamination risk.
- FAT & SAT Testing: Conducting thorough Factory and Site Acceptance Tests to validate functionality before production.
- Documentation & Drawings: Providing electrical schematics, panel layout diagrams, and BOMs for reference and troubleshooting.
Upgrades, Retrofits & Migrations
- Legacy Migrations & Obsolescence: Removal of end-of-life hardware and unsupported systems to prevent downtime risks, ensure replacement parts availability, and secure long-term reliability through modern, vendor-supported solutions.
- Hardware & Software Upgrades: Incorporating new controllers, drives, sensors, or automation software to boost system reliability, integrate modern features, and future-proof operations.
- Retrofits & Expansions: Enhancing or reconfiguring existing equipment and systems to meet evolving production demands, address obsolescence, and capitalize on new market opportunities—all while managing costs and downtime through planned rollouts.
- Parallel Testing & Commissioning: Running new solutions in tandem with existing setups to minimize operational interruptions and verify functionality before full cutover.
- Hardware & Software Standardization: Unifying multiple control platforms, operating versions, and communication protocols to simplify maintenance, reduce training overhead, and streamline spare parts management.
- Phased Implementation Strategies: Scheduling major updates—mechanical, electrical, or software-related—over planned outages or staggered deployments, ensuring production continuity and optimized resource usage.
- Post-Upgrade Support & Optimization: Providing ongoing support after modernization, including system tuning, operator training, and performance reviews to ensure a smooth transition and long-term success.
Maintenance & Support Services
- Preventive Maintenance Programs
Regularly scheduled inspections and servicing to minimize downtime and extend equipment lifespan.
- 24/7 Technical Support & Emergency Response (with Support Contract)
Round-the-clock assistance to address urgent issues, available to clients who opt for a support contract.
- Post-Project Support
Included with every project to ensure a seamless handover and immediate troubleshooting once the system goes live.
- Field Services
Rapid dispatch of technicians to diagnose equipment issues, perform repairs, and restore functionality—minimizing disruption and downtime.
- Remote Monitoring & Troubleshooting
Real-time tracking of system performance to detect and resolve potential issues before they escalate.
- Staff Augmentation
Access to skilled professionals to fill short-term or specialized staffing needs for ongoing or complex projects.
- Software & System Upgrades
Regular updates to maintain optimal performance, ensure compatibility, and address emerging security concerns.
- Employee Training & Knowledge Transfer
Comprehensive support for in-house teams, covering best practices and hands-on training.
- Compliance & Safety Support
Guidance on meeting regulatory requirements and maintaining best practices for safe operation.
- Lifecycle & Asset Management
Proactive planning for equipment upgrades and replacements to optimize total cost of ownership.
Featured Projects
Case Study
RESTORING PRECISION: Upgrading Vision Systems For Reliable Barcode Validation
Case Study
KEEPING THE LINE FLOWING: Restoring Brewery Operations
Case Study
NEW RECIPE CONTROLS SYSTEM: Automating & Upgrading the Food Seasoning Process for Fuji Foods, Inc.
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