FOOD, BEVERAGES & CHEMICAL PROCESS INDUSTRIES
Food, Beverages & Chemical Process Industries
Industry Overview
- The Food, Beverages & Chemical Process Industries sector encompasses industrial facilities involved in the processing, conversion, formulation, separation, treatment, blending, packaging and storage of food, beverage and chemical products.
- The sector covers continuous, batch and semi-batch process environments where raw materials are converted into intermediate or finished products through controlled physical, chemical, thermal, biological and mechanical processes.
- It includes food and beverage processing plants, dairy and edible-oil facilities, breweries and beverage plants, packaged-food manufacturing, specialty and industrial chemical plants, formulation and blending facilities, bulk chemical storage and associated utility and wastewater systems.
General Process Architecture
Although individual products have different manufacturing routes, the common industrial process logic can be represented as:
General Process Architecture
For food and beverage facilities, the process may additionally involve:
For chemical-process facilities, the process may instead involve:
Major Industrial Applications
The major industrial applications of the sector cover food processing, beverage, dairy and edible oil and fat industries, chemical process industries, formulation, blending and specialty chemical manufacturing, bulk chemical storage and handling, and the utilities, cleaning and environmental systems that support them.
1. Food Processing Industries
- Processed food manufacturing
- Grain and cereal processing
- Flour and starch processing
- Bakery and confectionery
- Processed fruits and vegetables
- Ready-to-eat / ready-to-cook food
- Meat and poultry processing
- Frozen food processing
- Dairy and dairy-product processing
- Food ingredient manufacturing
2. Beverage Industries
- Soft-drink manufacturing
- Juice and fruit beverage processing
- Bottled-water plants
- Dairy beverages
- Brewing and beverage-processing facilities
- Beverage blending and formulation
- Filling and packaging facilities
3. Dairy Processing
- Milk reception and chilling
- Pasteurization
- Homogenization
- Cream separation
- Milk powder production
- Butter and ghee processing
- Cheese production
- Yogurt / fermented-product processing
- Dairy-product filling and packaging
4. Edible Oil & Fat Processing
- Vegetable-oil extraction
- Oil refining
- Degumming
- Neutralization
- Bleaching
- Deodorization
- Fractionation
- Hydrogenation, where applicable
- Oil blending and packaging
5. Chemical Process Industries
- Industrial chemicals
- Specialty chemicals
- Organic chemicals
- Inorganic chemicals
- Chemical intermediates
- Solvents
- Acids and alkalis
- Formulation chemicals
- Performance chemicals
- Process additives
6. Formulation, Blending & Specialty Chemical Manufacturing
- Batch formulation
- Chemical blending
- Dosing and mixing
- Specialty chemical production
- Additive manufacturing
- Resin / polymer formulation
- Coatings and related chemical formulations
- Detergent and cleaning chemical manufacturing
7. Bulk Chemical Storage & Handling
- Liquid chemical storage
- Bulk chemical terminals
- Tank farms
- Chemical transfer systems
- Loading / unloading facilities
- Drum and IBC handling
- Chemical distribution facilities
8. Utilities, Cleaning & Environmental Systems
- Steam generation
- Hot-water systems
- Refrigeration
- Chilled-water systems
- Compressed air
- Process water
- CIP systems
- Water treatment
- Effluent treatment
- Wastewater treatment
- Waste handling
Major Units, Facilities, Systems & Packages
The following sections set out the major units, facilities, systems and packages of the Food, Beverages & Chemical Process Industries sector, covering food, dairy, beverage, edible oil and chemical process plants and the storage, cleaning, refrigeration, utility, wastewater, packaging and project systems that support them.
| Ref. | Section | Groups |
|---|---|---|
| 1 | Raw Material Receiving & Storage | Receiving FacilitiesStorage FacilitiesMaterial Handling |
| 2 | Food Processing Systems | PreparationThermal ProcessingProcess EquipmentConcentration / Drying |
| 3 | Dairy Processing Facilities | Milk Reception & PreparationProcessingProduct ManufacturingFilling & Packaging |
| 4 | Beverage Processing Facilities | Water Treatment & PreparationBeverage PreparationThermal / Process TreatmentFilling & Packaging |
| 5 | Edible Oil Processing | Oil Extraction / ReceptionRefiningFurther ProcessingStorage & Packaging |
| 6 | Chemical Process Plants | Raw Material PreparationReaction / ConversionSeparationPurificationProduct Formulation |
| 7 | Specialty Chemical & Formulation Plants | Batch ManufacturingBlending / FormulationProduct FinishingChemical Storage |
| 8 | Bulk Chemical Storage & Transfer | StorageTransferLoading Facilities |
| 9 | CIP, Cleaning & Hygiene Systems | CIP SystemsCleaning / SanitizationHygienic Process Systems |
| 10 | Refrigeration & Cold-Chain Systems | Systems listed directly under this section |
| 11 | Utilities & Off-Site Facilities | Steam & HeatingWaterAir & GasElectrical |
| 12 | Wastewater & Environmental Systems | Effluent TreatmentFood / Beverage WastewaterChemical Wastewater |
| 13 | Packaging & Finished Product Handling | Food / BeverageChemical Products |
| 14 | Brownfield, Expansion & Shutdown Projects | Plant ExpansionEquipment ReplacementModification / RevampShutdown / Maintenance |
1. Raw Material Receiving & Storage
Raw material receiving and storage is where materials enter the plant and are held before processing. The groups below cover the receiving facilities, the storage facilities, and the material handling equipment that moves, doses and weighs materials between them.
Receiving Facilities
- Raw material receiving stations
- Truck unloading systems
- Bulk liquid unloading
- Bag / sack receiving
- Drum unloading
- IBC unloading
- Material inspection and sampling facilities
Storage Facilities
- Raw material storage tanks
- Silos
- Bins
- Hoppers
- Cold storage
- Refrigerated storage
- Warehouse storage
- Chemical storage tanks
- Drum / IBC storage
Material Handling
- Conveyors
- Screw conveyors
- Bucket elevators
- Pneumatic conveying
- Pumps
- Transfer systems
- Dosing systems
- Weighing systems
2. Food Processing Systems
Food processing systems prepare raw materials, apply heat, carry out the main processing, and concentrate or dry the product. The groups below cover preparation, thermal processing, process equipment, and concentration / drying.
Preparation
- Cleaning systems
- Washing systems
- Sorting systems
- Grading systems
- Peeling / cutting systems
- Crushing / grinding systems
- Milling systems
- Mixing systems
Thermal Processing
- Pasteurizers
- Sterilizers
- Retorts
- Cooking systems
- Blanchers
- Steam-heating systems
- Heat exchangers
Process Equipment
- Mixers
- Agitators
- Blenders
- Process vessels
- Holding tanks
- Processing tanks
- Homogenizers
- Separators
- Filters
Concentration / Drying
- Evaporators
- Concentrators
- Spray dryers
- Tray dryers
- Fluid-bed dryers
- Vacuum drying systems
3. Dairy Processing Facilities
Dairy processing facilities receive and prepare milk, process it, convert it into dairy products, and fill and package the finished products. The groups below cover each of these stages.
Milk Reception & Preparation
- Milk reception systems
- Milk storage tanks
- Chilled milk tanks
- Milk filtration
- Cream separators
- Standardization systems
Processing
- Pasteurization systems
- Homogenizers
- Heat exchangers
- Holding tubes
- Process vessels
- Fermentation tanks
Product Manufacturing
- Yogurt / fermented-product systems
- Cheese processing systems
- Butter processing systems
- Milk powder systems
- Cream processing systems
Filling & Packaging
- Bottle filling
- Pouch filling
- Carton filling
- Cup filling
- Product sealing
- Packaging systems
4. Beverage Processing Facilities
Beverage processing facilities treat and prepare water, make and blend the beverage, apply thermal / process treatment, and fill and package the product. The groups below cover each of these stages.
Water Treatment & Preparation
- Raw-water treatment
- Filtration
- RO systems
- UV treatment
- Ozone systems, where applicable
- Treated-water storage
Beverage Preparation
- Syrup preparation
- Sugar dissolving systems
- Ingredient dosing
- Blending systems
- Carbonation systems
- Beverage mixing
- Product holding tanks
Thermal / Process Treatment
- Pasteurization
- Sterilization
- Heat exchangers
- Product cooling systems
Filling & Packaging
- Bottle filling
- Can filling
- Pouch filling
- Capping
- Labelling
- Shrink wrapping
- Case packing
- Palletizing
5. Edible Oil Processing
Edible oil processing takes oilseed through extraction, refining and further processing, and then stores and packs the refined oil. The groups below cover oil extraction / reception, refining, further processing, and storage & packaging.
Oil Extraction / Reception
- Oilseed receiving
- Seed cleaning
- Crushing / preparation
- Extraction systems
- Crude oil storage
Refining
- Degumming
- Neutralization
- Bleaching
- Filtration
- Deodorization
Further Processing
- Fractionation
- Hydrogenation, where applicable
- Blending
- Product conditioning
Storage & Packaging
- Refined oil storage tanks
- Transfer systems
- Filling systems
- Bottle / pouch packaging
- Bulk loading systems
6. Chemical Process Plants
Chemical process plants convert raw materials into chemical products through preparation, reaction, separation, purification and formulation. The groups below set out the units and systems under each stage.
Chemical plants may be organized around batch, continuous or semi-continuous production depending on the product and process.
Raw Material Preparation
- Raw material storage
- Feed tanks
- Day tanks
- Dosing systems
- Chemical transfer systems
- Feed preparation
- Preheating / conditioning
Reaction / Conversion
- Reactors
- Reaction vessels
- Agitated reactors
- Batch reactors
- Continuous reactors
- Polymerization reactors
- Hydrogenation systems
- Reaction heating / cooling systems
Separation
- Distillation columns
- Fractionation systems
- Evaporators
- Separators
- Centrifuges
- Filters
- Filter presses
- Membrane separation systems, where applicable
Purification
- Purification vessels
- Adsorption systems
- Ion-exchange systems
- Crystallization systems
- Solvent recovery
- Drying systems
Product Formulation
- Mixing tanks
- Blending systems
- Agitated vessels
- Dosing systems
- Additive injection
- Product conditioning
7. Specialty Chemical & Formulation Plants
Specialty chemical and formulation plants manufacture in batches, blend and formulate products, finish them, and store them. The groups below cover batch manufacturing, blending / formulation, product finishing and chemical storage.
Batch Manufacturing
- Batch reactors
- Mixing vessels
- Agitators
- Holding tanks
- Dosing systems
- Transfer pumps
Blending / Formulation
- High-shear mixers
- Ribbon blenders
- Paddle mixers
- Liquid blending systems
- Powder blending systems
- Dosing systems
Product Finishing
- Filtration
- Drying
- Grinding
- Milling
- Sieving
- Pelletizing, where applicable
- Filling and packaging
Chemical Storage
- Bulk storage tanks
- Day tanks
- Intermediate storage
- Drum filling
- IBC filling
- Chemical loading systems
8. Bulk Chemical Storage & Transfer
Bulk chemical storage and transfer covers the tanks that hold chemicals, the systems that move them, and the facilities that load them out. The groups below cover storage, transfer and loading facilities.
Storage
- Atmospheric storage tanks
- Chemical storage tanks
- Special-material storage tanks
- Day tanks
- Intermediate storage tanks
- Drum / IBC storage
Transfer
- Chemical transfer pumps
- Loading / unloading systems
- Transfer piping
- Valves
- Metering systems
- Dosing systems
Loading Facilities
- Tanker loading
- Tanker unloading
- Drum filling
- IBC filling
- Bulk dispatch systems
9. CIP, Cleaning & Hygiene Systems
CIP, cleaning and hygiene systems keep process equipment clean and sanitary. The groups below cover CIP systems, cleaning / sanitization, and hygienic process systems.
Particularly important in food, beverage and dairy facilities.
CIP Systems
- CIP tanks
- Caustic solution tanks
- Acid solution tanks
- Rinse-water systems
- CIP pumps
- Heat exchangers
- Chemical dosing
- CIP circulation systems
Cleaning / Sanitization
- Hot-water systems
- Steam systems
- Sanitization systems
- Process-line flushing
- Cleaning chemical systems
Hygienic Process Systems
- Hygienic piping
- Sanitary valves
- Sanitary pumps
- Hygienic tanks
- Product-contact equipment
10. Refrigeration & Cold-Chain Systems
Refrigeration and cold-chain systems provide the cooling and cold storage the plant needs. The items below cover the refrigeration plant, the chilled-water and cooling systems, and the cold storage facilities.
Refrigeration & Cold-Chain Systems
- Refrigeration compressors
- Condensers
- Evaporators
- Chillers
- Chilled-water systems
- Cold rooms
- Freezers
- Refrigerated storage
- Refrigerant piping
- Cooling-water systems
These systems are particularly relevant to dairy, meat, frozen-food, beverage and temperature-sensitive food processing.
11. Utilities & Off-Site Facilities
Utilities and off-site facilities support the process areas with steam and heating, water, air and gas, and electrical supply. The groups below cover each of these.
Steam & Heating
- Boilers
- Steam generation
- Steam distribution
- Hot-water systems
- Thermal-oil systems, where applicable
Water
- Raw-water treatment
- RO
- DM / demineralization
- Process-water systems
- Potable-water systems
- Storage tanks
Air & Gas
- Instrument air
- Plant air
- Air compressors
- Air receivers
- Air dryers
- Nitrogen systems
Electrical
- Transformers
- Switchgear
- MCCs
- Distribution panels
- Emergency power
- DG sets
- UPS systems
12. Wastewater & Environmental Systems
Wastewater and environmental systems treat and handle the effluent and waste the plant produces. The groups below cover general effluent treatment, food / beverage wastewater, and chemical wastewater.
Effluent Treatment
- Effluent collection
- Equalization tanks
- Neutralization systems
- Clarifiers
- Biological treatment
- Filtration
- Sludge handling
Food / Beverage Wastewater
- Organic-load treatment
- Fat / oil separation
- Sludge handling
- Wastewater recovery / reuse, where applicable
Chemical Wastewater
- Chemical neutralization
- Process wastewater treatment
- Hazardous / chemical waste handling
- Solvent recovery, where applicable
13. Packaging & Finished Product Handling
Packaging and finished product handling covers the equipment used to fill, seal, pack and dispatch finished products. The groups below cover food / beverage products and chemical products.
Food / Beverage
- Filling machines
- Capping machines
- Sealing systems
- Labelling
- Cartoning
- Case packing
- Palletizing
Chemical Products
- Drum filling
- IBC filling
- Bagging
- Powder filling
- Liquid filling
- Container sealing
- Product weighing
- Dispatch systems
14. Brownfield, Expansion & Shutdown Projects
This section covers work on existing plants: expansion, equipment replacement, modification / revamp, and shutdown / maintenance. The groups below set out the items under each.
Plant Expansion
- Additional process lines
- New reactors / vessels
- Additional tanks
- New filling / packaging lines
- Utility expansion
- Refrigeration expansion
- Electrical expansion
Equipment Replacement
- Process equipment replacement
- Pumps
- Compressors
- Heat exchangers
- Tanks
- Valves
- Electrical equipment
- Packaging machinery
Modification / Revamp
- Process piping modification
- Utility modification
- CIP modification
- Electrical modification
- Equipment relocation
- Production-capacity enhancement
Shutdown / Maintenance
- Equipment inspection
- Tank inspection
- Pressure testing
- Piping inspection
- Cleaning / reinstatement
- Functional testing
- Recommissioning
Sector wise Commodities
The Food, Beverages & Chemical Process sector has a broad equipment universe extending from metallic raw materials and fabricated process equipment to rotating machinery, process valves, utility systems and electrical equipment.
For IQAS, these items can be considered through the applicable SS17, SS18 and SS19 classification framework.
SS17
Basic Metals & Fabricated Metal Products
- Raw Materials
- Process Piping & Components
- Fabricated Products
- Static & Process Equipment
- Food / Hygienic Fabrication
- Fabrication & Welding
SS18
- Pumps
- Compressors & Air Equipment
- Process Machinery
- Thermal / Process Equipment
- Valves
- Material Handling
- Skid / Package Equipment
SS19
Electrical & Optical Equipment
- Power Generation & Backup
- Transformers & Distribution
- Electrical Machines
- Cables & Protection
- Automation-Related Electrical Equipment
- Earthing & Lightning Protection
SS17 – Basic Metals & Fabricated Metal Products
SS17 — Basic Metals & Fabricated Metal Products covers the following categories for this sector: Raw Materials, Process Piping & Components, Fabricated Products, Static & Process Equipment, Food / Hygienic Fabrication and Fabrication & Welding. The items under each category are listed below.
Raw Materials
- Plates & Sheets
- Pipes & Tubes
- Bars
- Forgings
- Castings
Piping Components
- Process Pipes
- Stainless Steel Piping
- Hygienic / Sanitary Piping, where applicable
- Pipe Fittings
- Flanges
- Fasteners
- Gaskets
Fabricated Steel Products
- Structural Steel
- Platforms
- Walkways
- Gratings
- Equipment Supports
- Frames
- Pipe Racks
- Fabricated Skids / Structures
Static & Pressure Equipment
- Boilers
- Steam Drums
- Pressure Vessels
- Deaerators
- Heat Exchangers
- Condensers
- Feedwater Heaters
- Air Receivers
- Storage Tanks
- Cooling-water tanks
- Fuel storage tanks
Food / Hygienic Fabrication
- Stainless-steel process equipment
- Sanitary tanks
- Hygienic piping
- Product-contact fabricated components
- Process skids
- Welded fabrication
Fabrication & Welding
- Welding inspection
- WPS / PQR / WPQ
- NDT
- Dimensional inspection
- Material traceability
- Surface / finish verification
- Pressure-testing records
SS18 – Machinery & Equipment
SS18 — Machinery & Equipment covers the following categories for this sector: Pumps, Compressors & Air Equipment, Process Machinery, Thermal / Process Equipment, Valves, Material Handling and Skid / Package Equipment. The items under each category are listed below.
Pumps
- Centrifugal Pumps
- Positive Displacement Pumps
- Sanitary Pumps
- Process Pumps
- Transfer Pumps
- Dosing Pumps
- CIP Pumps
- Water Pumps
- Chemical Pumps
Compressors & Air Equipment
- Air Compressors
- Process Compressors
- Refrigeration Compressors
- Blowers
- Vacuum Pumps
- Air Receivers
Process Machinery
- Mixers
- Agitators
- Homogenizers
- Separators
- Centrifuges
- Grinding Mills
- Crushers
- Conveyors
- Packaging Machinery
Thermal / Process Equipment
- Pasteurizers
- Sterilizers
- Retorts
- Evaporators
- Dryers
- Spray Dryers
- Heat Exchangers
- Chillers
- Refrigeration Equipment
- Cooling Towers
Valves
- Gate Valves
- Globe Valves
- Ball Valves
- Butterfly Valves
- Check Valves
- Control Valves
- Sanitary / Hygienic Valves
- Diaphragm Valves
- Other applicable process valves
Material Handling
- EOT Cranes
- Hoists
- Conveyors
- Lifting Equipment
- Applicable lifting accessories
Skid / Package Equipment
- CIP Packages
- Water Treatment Packages
- RO Packages
- Chemical Dosing Packages
- Refrigeration Packages
- Air Compressor Packages
- Filtration Packages
- Process Skids
- Pump Packages
SS19 – Electrical & Optical Equipment
SS19 — Electrical & Optical Equipment covers the following categories for this sector: Power Generation & Backup, Transformers & Distribution, Electrical Machines, Cables & Protection, Automation-Related Electrical Equipment and Earthing & Lightning Protection. The items under each category are listed below.
Power Generation & Backup
- Generators
- DG Sets
- UPS
- Emergency Power Equipment
Transformers & Distribution
- Power Transformers
- Distribution Transformers
- LV Switchgear
- MV Switchgear
- MCCs
- Electrical Panels
- Distribution Boards
Electrical Machines
- Motors
- Process Motors
- Pump Motors
- Compressor Motors
- Fan Motors
- Electrical Drives
Cables & Protection
- HV / MV / LV Cables, as applicable
- Power Cables
- Control Cables
- Circuit Breakers
- Protection Relays
- Electrical Protection Equipment
Automation-Related Electrical Equipment
- Motor Control Equipment
- Control Panels
- Electrical interface equipment
- Applicable industrial control / electrical assemblies within scope
Earthing & Lightning Protection
- Earthing Equipment
- Earthing Conductors
- Lightning Protection Equipment
- Associated protection components
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