The Engineering Challenge
Operating at high filling speeds across carbonated soft drink (CSD) lines requires uninterrupted syrup preparation with uncompromising standard operating consistency. Traditional batch dissolving tanks introduce thermal loss, high steam demand, manual handling variations, and batch-to-batch Brix deviation.
MBH Solutions was contracted to execute the mechanical fabrication, orbital sanitary piping, electrical integration, and automated startup of a 40,000 L/h continuous dissolving system, sanitary storage matrix, and dedicated 4-circuit CIP station.
Technical Architecture & Execution Scope
The delivery encompassed end-to-end skid fabrication and process integration compliant with stringent The Coca-Cola Company Engineering Specifications (TCCC-GEC):
- Continuous Dissolving Skid: High-shear powder induction mixer paired with plate heat exchangers to achieve complete 65° Brix simple syrup dissolution in a single pass at lower thermal operating temperatures.
- ASME BPE Sanitary Orbital Piping: 100% video-boroscope inspected orbital TIG welding of 316L stainless steel process lines, ensuring ultra-smooth fluid pathways free from microbial crevices.
- Mixproof Valve Manifolds: Configured GEA double-seat mixproof valve arrays preventing cross-flow between raw syrup preparation, pasteurization holding tubes, and active CIP sanitization loops.
- Pumping & Metering Infrastructure: Installed Fristam centrifugal and sanitary positive displacement pumps driven by Danfoss VLT AutomationDrives, regulated via Endress+Hauser electromagnetic flowmeters.
- Closed-Loop Brix Telemetry: Maselli inline optical refractometers feeding real-time density readings into a central Siemens S7-1500 PLC for dynamic micro-adjustments.
Performance Metrics & Operational Results
| Process Parameter | Batch Baseline | Continuous Automated System |
|---|---|---|
| Brix Stability Tolerance | ±0.45° Brix (manual tank adjustments) | ±0.05° Brix (closed-loop control) |
| Continuous Dissolving Throughput | 18,000 L/h (intermittent batches) | 40,000 L/h continuous delivery |
| Steam & Thermal Energy Usage | High heat dissipation in open dissolving | 18.5% reduction via heat regeneration |
| Sanitation Cycle Turnaround | 3.8 hours manual pipe flushing | 2.1 hours automated 4-circuit CIP |
Frequently Asked Engineering Questions
How does continuous hot/cold sugar dissolving maintain consistent Brix levels?
Continuous dissolving systems utilize inline optical refractometers (such as Maselli) installed downstream of the shearing mixer. The unit continuously monitors dissolved solids and feeds high-frequency analog signals into a PID loop, instantly adjusting the dry sugar rotary feeder and treated water modulating valve to maintain Brix within ±0.05° of target.
What welding standards are applied to sanitary 316L beverage process piping?
All stainless steel process piping conforms to ASME BPE standards utilizing automated orbital TIG welding with inert argon purging. Each weld joint is 100% boroscope inspected to verify full penetration and internal surface smoothness under Ra < 0.8 µm, preventing bacterial harbor points.