Auto Foam Cleaning System Recovery

Industry: Food & Beverage

Case Study

Auto Foam Cleaning System Recovery

Assessment, restoration, and optimisation of an aging automated cleaning system.

The Situation

A 12-year-old foam cleaning system had progressively failed, with internal teams unable to restore functionality. OEM support was no longer available.

Challenge:

Significant equipment deterioration over time

Lack of system knowledge and documentation

Multiple mechanical and pneumatic failures

Reduced cleaning performance, impacting QA outcomes

Approach:

Future Electrix carried out a full system assessment and restoration, including:

Validation of PLC and HMI backups

Full I/O and system functionality checks

Identification of root causes, including:

  • Valve actuator failures
  • Incorrect installations and pneumatic connections
  • Blocked chemical delivery systems
  • Faulty regulators

Updated documentation and system understanding

The Outcome​

Restored full system functionality

Reduced manual cleaning and operator intervention

Improved safety through reduced chemical exposure

Consistent QA outcomes with reliable cleaning cycles

Clear documentation for ongoing maintenance and support

Utilising the latest technology to develop innovative programming and upgrade existing systems.

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