A heat exchanger integrity test keeps the sweetening formula production running with no interruptions

The sweet formula producer relied on 14 gasketed plate heat exchangers as a key part of production but followed a reactive maintenance strategy. This has led to declining equipment performance and recurring unpredictable shutdowns, that the customer wanted to put an end to.

Challenge

The customer historically adopted a corrective maintenance approach for their gasketed heat exchangers. This reactive strategy led to declining equipment performance and recurring operational issues that required unpredictable production shutdowns to resolve.

These interruptions increased operating costs and created uncertainty in maintenance planning. Without visibility into the internal condition of the heat exchangers, the customer struggled to anticipate failures or improve service intervals. A reliable diagnostic method was needed to assess equipment condition and shift toward preventive maintenance.

Solution

Alfa Laval recommended conducting a comprehensive heat exchanger integrity test to evaluate the condition of the customer’s gasketed plate heat exchangers without opening the units. This non-intrusive assessment minimized downtime while providing accurate insights into the condition of the plate.

Fourteen heat exchangers were tested, and the results showed that all units required repair. Based on these findings, Alfa Laval implemented a structured service plan that included:

• Professional reconditioning of heat exchangers at the service center
• Controlled reinstallation to restore operational performance
• On-site training for plant personnel to support long-term maintenance practices

This integrated approach ensured that diagnostic insights from the heat exchanger integrity test translated directly into corrective actions and improved asset reliability.

Results

The integrity testing program delivered actionable data that allowed the customer to proactively schedule maintenance rather than react to failures.

Key outcomes included:

• 100% reduction of unexpected shutdowns due to GPHE failures
• Improved maintenance planning and cost control
• Lower overall operational expenses

By leveraging the heat exchanger integrity test, the customer transitioned to a preventive maintenance strategy that strengthened operational stability and minimized production disruptions.

Outlook

This case highlights how preventive maintenance supported by a heat exchanger integrity test can transform plant reliability. Early detection of internal equipment issues enables smarter service planning, reduces operational and maintenance costs, and ensures production continuity.

For food industry operators, adopting proactive diagnostics and structured maintenance programs creates a foundation for long-term efficiency, predictable operations, and sustained product quality.