Checking heat exchanger integrity is an important part of protecting product quality. But testing also needs to fit around the practical demands of a busy processing facility.
Pastest+ is Unison’s non-destructive testing system for assessing heat exchanger integrity without dismantling the equipment. In this guide, we explain how it works, what it checks and how the results help customers make informed maintenance decisions.
What is heat exchanger integrity testing?
Integrity testing checks for leaks or defects that could compromise the separation between fluids within a heat exchanger and cause product loss due to cross contamination.
For food and beverage processors, a defect can have implications for product quality and safety. Integrity testing provides information about equipment condition so that issues can be investigated and appropriate action taken.
It should sit alongside routine monitoring, cleaning and maintenance as part of the facility’s wider equipment management programme.
What is Pastest+?
Pastest+ is Unison’s patented, non-destructive integrity testing and holding time verification system for pasteurisers, plate heat exchangers and tubular heat exchangers.
The system allows integrity testing without dismantling the exchanger’s plate pack. This provides a way to assess integrity before deciding whether opening the equipment and carrying out further inspection is necessary.
Pastest+ has been validated by Campden BRI, an independent food and drink research organisation. It combines testing with digital reporting, giving customers access to documented results for their equipment.
How does Pastest+ work?
Pastest+ monitors pressure changes within the heat exchanger to identify leakage. Testing can use process water or gas, with the appropriate method selected for the equipment and application.
Rather than relying on dismantling the unit as the first step, the system assesses integrity while the exchanger remains assembled.
Results are available following the test, helping the team determine the next action. If testing identifies a potential defect, further investigation is required to establish the problem and the appropriate repair.
The findings help determine whether further inspection, servicing or repairs are required.
What about holding time verification?
For pasteurisation equipment, Pastest+ also provides holding time verification.
Pasteurisation depends on a defined combination of temperature and exposure time. Holding time verification checks the time element of that process, supporting assessment of whether the pasteuriser is operating as intended.
How are results recorded?
Clear records are important when managing multiple heat exchangers, maintenance activities and testing dates.
Pastest+ generates digital test certificates, with results accessible through its web portal. QR code equipment labels provide a link to the relevant records, and reports can be sent by email.
This gives maintenance and quality teams a practical way to retrieve test information without relying solely on handwritten records. Linking results to the equipment also helps maintain a documented history for future reference.
For example, when planning a service, the team can review previous test records alongside repair information and operating data.
What are the benefits for customers?
- Less dismantling for testing
Testing an assembled exchanger can reduce the work involved in assessing integrity and therefore minimise downtime for the plant. Where a defect is identified, opening the equipment may still be necessary.
- Better-informed maintenance decisions
Results help teams decide when further investigation is needed and provide a clearer basis for discussing repairs.
- Accessible equipment records
Digital certificates and QR-linked information make it easier to find and share testing records.
- Support for maintenance planning
Test results give maintenance teams information to help prioritise further inspections and plan any necessary work. The value comes from using the results: reviewing findings, investigating failures and incorporating the information into maintenance planning.
Discuss Pastest+ with Unison
Whether you are reviewing your current testing arrangements or exploring Pastest+ for your facility, start with the equipment you need to assess and the information your team requires.
Our team can discuss the application, testing options and how Pastest+ could fit into your maintenance programme.
Contact Unison Process Solutions to arrange a demonstration or discuss your heat exchanger integrity testing requirements.