Smarter Scaling with Food and Beverage Process Engineering

The food and beverage industry operates under some of the toughest regulations to protect public health and safety. 

For companies, this means constantly monitoring processes and finding ways to improve—a challenge that’s easier said than done.

That’s where food and beverage process engineering comes in.

This field is the backbone of the industry, driving everything from safety and hygiene to sustainable production methods. Whether meeting compliance standards or scaling production efficiently, process engineering helps make it all possible.

The Role of Food and Beverage Process Engineering

It’s no secret that process engineering is essential to the food and beverage industry. Process engineering plays seven critical roles in this market:

1. Safety and hygiene
2. Quality control
3. Efficiency and productivity 
4. Innovation and product development
5. Environmental impact 
6. Compliance with standards and regulations
7. Consumer trends and scalability 

1.Safety and Hygiene

The food and beverage industry is under strict regulations through the FDA and other organizations to maintain good public health. Food processing engineers use several strategies to ensure safety and hygiene standards are met: 

• Designing hygienic processes and facilities: Food processing engineers design with hygiene in mind by selecting materials and surfaces that are easy to clean and maintain, designing layouts that prevent cross-contamination, and ensuring proper waste disposal systems. 
• Controlling contamination: Processing engineers ensure the safety of each process step by implementing systems to control contaminants and establishing critical control points where risks can be monitored and mitigated. 
• Establishing cleaning and sanitation protocols: Process engineers develop and enforce strict procedures for cleaning and sanitizing equipment. Typically, this includes selecting cleaning agents and setting cleaning schedules. 
• Regulating temperatures: By designing systems that monitor and control temperatures, food safety and bacterial growth concerns are mitigated.

2. Quality Control 

Quality control is an essential part of operations in any industry. Still, it is especially necessary for food and beverage safety. Food processing engineers implement quality control systems for each production stage to monitor and test food products. This includes inspecting for contamination, verifying shelf life, and checking products for specified safety criteria.

3. Efficiency and Productivity

Efficiency and productivity are essential in any production. Process engineering streamlines the production process, leading to more efficient operations. This can result in higher productivity, reduced waste, and lower production costs. 

4. Innovation and Product Development 

The latest technology or innovation is always around the corner in the food and beverage industry. Process engineers stay current on the latest methods, which leads to the creation of new products, improvements to existing ones, and exploration of new ways to enhance food preservation and shelf life. 

5. Environmental Impact

Maintaining a positive environmental impact is a goal in nearly every industry today. In the food and beverage sector specifically, it can leave a significant environmental footprint. 

Food processing engineers work to develop more sustainable and eco-friendly production methods and ways to lower waste, energy consumption, and emissions. 

6. Compliance with Standards and Regulations

Since the food and beverage industry has many standards, someone must ensure that production follows regulations. Process engineering helps ensure compliance with laws regarding food safety, labeling, and environmental impact. By working with a process engineer, you can avoid legal issues and maintain a good reputation.

7. Consumer Trends and Scalability

Keeping up with the latest trends can be challenging as business and consumer preferences evolve. Process engineering allows the food and beverage industry to adapt quickly to changes, whether shifting towards plant-based alternatives, organic needs, or a large influx of business. 

Types of Food and Beverage Process Equipment 

Mixers and blenders – used to blend, emulsify, and disperse ingredients. They come in various types, such as high-shear and low-shear mixers, each suitable for different mixing requirements. 

Pumps and heat transfer systems are often essential for food and beverage processing. Depending on the specific process requirements, these components can be mapped out using a Process Flow Diagram (PFD) to guarantee process accuracy. 

Tanks and vessels – store raw materials, mixing ingredients and other products. These can be designed for specific temperatures, limited contamination, and pressure. 

Homogenizers – blend immiscible liquids into an emulsion, frequently found in dairy and beverage production.

Automation and monitoring software includes:

• HMIs (human-machine interfaces)
• PLCs (programmable logic controllers)
• Flow meters
• Sensor equipment

All of the following equipment monitors flow rates and temperature throughout the process. All these give operators a higher level of control and management of their processes.

Scaling Your Business With Process Engineering 

Process engineering allows you to scale your food and beverage industry business through a strategic approach, balancing efficiency, quality, and capacity. Typically, food processing engineers follow these steps to scale your production:

Optimizing Existing Processes

Before considering expanding, you want to ensure your current processes are as efficient as possible. Process engineers will first optimize these processes, work to reduce waste, and increase productivity to lay a solid foundation for scaling success.

Capacity Analysis and Expansion

Process engineers conduct a capacity analysis to determine the maximum production capacity. This determines where facilities need to expand, upgrade equipment, automate processes, or redesign workflow.

Technology Integration

Automating your processes and integrating new technology will increase your production capacity. Automation reduces the need for manual labor, improves precision, and can operate continuously – even after hours. Process engineers assist with this essential part of scaling your production.

Quality Control Evaluations

There is a fine line between increasing production and maintaining high product quality. Process engineers make this much more manageable by ensuring that quality control systems are robust enough to handle increased production without compromising quality.

Supply Chain Management 

When you scale production, you’ll need a more complex supply chain. Process engineers optimize supply chain logistics, from raw material procurement to product distribution. Remember, without a functional supply chain, your production will halt. 

Scaling Production with Food and Beverage Process Engineering

Process engineering is essential for thriving in the highly regulated food and beverage industry, from ensuring safety and hygiene to adopting sustainable practices. You can scale production, maintain product quality, and meet your growth goals by leveraging process engineering.

Partnering with the right process engineering team is an investment in your company’s success. At MXD Process, we can help you elevate your operations. Ready to ramp up production? Contact us today to learn how we can support your journey.

(Editor's Note: This article was originally published in January 2016 and was recently updated.)