A survey of control system validation practices in the food industry

Abstract

Over the last decade, there has been a significant increase in use of digital control systems in the food manufacturing industry. The additional tasks with which digital controllers are burdened make their function much more complex than the electro-pneumatic-mechanical systems they replace. Potential control system failures can affect operator and process safety. Proper control system validation measures can prevent such potentially tragic failures. To our knowledge, there does not exist any published information regarding the validation practices within the food manufacturing industry. A nationwide scientific survey of US food manufacturers was conducted to determine such information. This survey also included system integrators and equipment suppliers that sell goods and services to the US food manufacturers. It has been determined that the majority of food manufacturers delegate the responsibility for control system validation to a third-party, such as equipment supplier, system integrator or a consulting firm, with little understanding of the validation process and its importance. Only a few food manufacturing companies utilize validation resources available from equipment suppliers and system integrators. Equipment suppliers and system integrators should combine their efforts to provide the food industry with formal and comprehensive training and maintenance programs for the equipment as well as the system that controls it.