This case study highlights the successful implementation of a custom-designed 5-ton/hour stainless steel mixing tank for a Fiji-based client supplying critical ingredients to PepsiCo’s beverage production line. The project focused on delivering a hygienic, high-efficiency mixing solution compliant with global food safety standards (ISO 22000, FDA). Key features included 316L stainless steel construction, automated temperature control, CIP integration, and precision agitation systems. The collaboration ensured seamless integration into PepsiCo’s existing workflow, enhancing production throughput while maintaining stringent quality benchmarks.
Project Overview
A leading Fiji-based beverage ingredient supplier partnered to design and install a 5-ton/hour stainless steel mixing tank for PepsiCo’s regional production facility. The client required a robust, food-grade solution to blend syrups and additives with precision, ensuring consistency in flavor and viscosity for PepsiCo’s carbonated drink line.
Challenges
1.Compliance: Adherence to PepsiCo’s Global Quality Standards (GQS) and hygienic design protocols.
2.Scalability: Handling 5 MT/hour without compromising mixing homogeneity.
3.Sanitation: Integration of Clean-in-Place (CIP) systems to minimize downtime.
4.Durability: Corrosion resistance in Fiji’s humid coastal environment.
Solution：
Custom-Engineered Mixing Tank:
Material: 316L stainless steel, electropolished interior (Ra ≤ 0.6 μm) for FDA/EC1935 compliance.
Agitation System: Variable-frequency drive (VFD) motor with 3-blade impeller (Reynolds number > 10⁵ for turbulent flow).
Temperature Control: Jacketed heating/cooling (-10°C to 95°C) via PLC automation.
CIP Integration: 360° spray ball system with 30-minute cycle time.
Safety: ATEX-certified explosion-proofing for ethanol-based additives.
Implementation
Design Phase: 3D modeling and CFD analysis optimized flow dynamics.
Testing: PepsiCo-approved microbial swab tests and material certifications.
Deployment: On-site installation with training for Fiji operational staff.
Results
Efficiency: Achieved 5.2 MT/hour throughput with ±1% viscosity variance.
Quality: Zero non-conformance reports (NCRs) in 12-month audits.
ROI: 18% reduction in energy use vs. client’s legacy system.
Client Feedback
"The tank’s seamless CIP functionality and durability in our tropical climate have been game-changers.PepsiCo’s QA team praised the consistency of outputs. "
– Production Manager, Fiji Client
Technical Specifications (Summary)
| Parameter | Detail |
| Capacity | 5 MT/hour (working volume 6,000L) |
| Material | 316L SS, ASME BPE-compliant |
| Pressure Rating | Full vacuum to 4 bar |
| Mixing Power | 15 kW motor, 0-100 rpm |
| Certifications | CE, ISO 9001/22000, FDA 21 CFR |
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