Case Studies

Turnkey Solution for Food and Beverage Product Testing

Posted in Business Intelligence, Digital Workplace Solutions, Food and Beverage, LabVIEW, Test & Measurement Automation, Test Stand


DMC designed and developed a custom test station and software for a beverage carbonator line to check for pressure leaks. The client needed a pressure decay test for a sub-assembly valve manifold in a restaurant-grade consumer appliance. DMC worked with the client to replicate and improve upon the manual test procedure, including interactive control and retesting ability. The product delivered was a complete, custom turn-key solution, involving mechanical, electrical and software engineering. Pressure data and pass-fail results are now published to a central data server for safe keeping and remote viewing.

DMC Concept Drawing

From Concept Drawing

DMC final product.

To Final Product

DMC main test screen

Valve Tray Tester

Valve Tray Tester

Valve Tray Tester


The client identified a part in their final product that was often the source of small CO2 leaks. They began hand-testing parts using a high-pressure cylinder but soon wanted to automate the process for increased safety and production speed. DMC engineers came on site and watched the current process, taking careful notes on problem areas and techniques. With our strong background in mechanical engineering, DMC specified pneumatic valves, connectors and tubing suitable for 150 psi operation. DMC also selected the appropriate pressure transducers and most cost-effective Data Acquisition device to both monitor and control the test bench. The test bench form factor mockup and test flowchart were then reviewed with the client before we began building. DMC worked with a partner for final electrical schematics and enclosure build.

On the software side, DMC developed the UI with usability in mind. The program supports a manual mode, for users to isolate and probe different part valves for easier leak detection. The Automatic Test sequence steps through the different test components, checking first for each valve’s functionality before quickly monitoring leak-rate on the manifold. If a leak is detected, users have the ability to pause the test to investigate, depressurize and tighten components before continuing. The main test allows pressure to stabilize, then monitors pressure drop over a given timeframe. Start and limits are clearly marked on the screen for user observation. Estop or abort at any time will vent the entire system and place it in a safe state.

After the test is complete, the operator has the option to log data and results to a central database. The relational database tables link sub-assembly pieces up with final shipped parts. Editable test parameters, such as maximum allowable pressure drop, can be setup through password protected configuration screen.

Designed and built with a flexible software and hardware architecture, DMC was able to ensure that new functionality, modifications, and upgrades could easily be added. 

Learn more about DMC's test and measurement services.

Customer Benefits

  • Increased line speed
  • Smart design eliminates extraneous test time
  • Improved efficiency through improved data processing and display
  • Increased line safety via clear User Interface Design
  • End-to-end project ownership