Choosing Controllers and Recorders for Food & Beverage Production

Food and beverage manufacturers produce and ship thousands of items daily, making technology selection critical for consistent quality and safety. This guide explains the key factors to consider when choosing controllers and recorders for food and beverage processes.

Regulators focus on safety and traceability, not the specific device. The goal is to guarantee safe products and enable swift identification of any issues.

Traceability is paramount. Incidents like the Sudan 1 dye contamination demonstrate the need for systems that can trace faults back to their source, identifying affected batches and allowing rapid risk mitigation.

Repeatability drives quality. Unlike many sectors, food producers work in large batches. Multi‑recipe controllers keep each product on a strict formula, ensuring ingredient and cooking profiles remain consistent.

Modern control options range from simple single‑loop controllers to sophisticated, feature‑rich systems. Yet the selection boils down to a few core criteria:

Problem‑Solving Automation

Time and temperature are critical variables. Automation allows operators to program variables in advance, so the system regulates the process based on predetermined rules. For example, a multi‑recipe controller can stop, alarm, or restart a process if steam supply fails during a 20‑minute cycle.

Automated response reduces human error, improves product quality, and cuts waste.

Operator‑Friendly Design

Plant operators, not buyers, handle the equipment daily. Choosing devices that sit on the plant floor—IP65 or IP66 protected, equivalent to NEMA 3/4—minimises cable clutter and maintenance.

Information display matters. Experienced batch operators rely on clear charts; electronic recorders with large displays (e.g., ABB’s ScreenMaster 3000, 30 cm screen) replicate the visual impact of paper charts while offering digital convenience.

Electronic recorders store data on memory cards or other media, making retrieval simple. This supports quick batch audits, trend analysis, preventive maintenance, and asset management.

Traceability & Regulatory Compliance

Regulators value accountability. The U.S. FDA’s 21 CFR Part 11 sets standards for electronic records, covering security, electronic signatures, and data integrity. Though not legally binding outside the U.S., it has become a global benchmark.

Modern videographic recorders (e.g., ABB’s SM series) satisfy these requirements: password protection, user‑specific access, audit trails, and time‑stamped electronic signatures.

Data integrity is preserved via binary encryption, and specialized software enables easy download and analysis of process data.

Microbial Safety & Process Optimization

Microbial contamination is the primary concern in food production. Heat treatment is most effective at higher temperatures. The F‑value—a logarithmic function—captures the relationship between temperature, time, and microbial kill.

Incorporating F‑value calculations into recorders allows producers to optimise sterilisation: a 1 °C increase from 121 °C to 122 °C can cut sterilisation time by 26 %.

Energy Efficiency & Cost Savings

Fuel costs and environmental taxes make energy efficiency critical. According to the Carbon Trust, advanced control and monitoring can yield 2–6 % energy savings on typical UK industrial sites.

When combined with reduced waste and improved process control, the economic and environmental benefits are compelling.

Ready to upgrade your plant’s control and recording systems? Explore ABB’s range of solutions at www.abb.com.