Liquids & Drinks · CSD & Juice

Carbonation Consistency

Cut CO2 volume variance by 74% and eliminate dissolved oxygen exceedances that flatten product in trade.

−74%

CO2 Volume Variance

Standard deviation of CO2 vols reduced from 0.28 to 0.073 across all SKUs in the pilot portfolio

−89%

DO Exceedances

Dissolved oxygen events above 60ppb dropped from 8.4 per shift to under 1 per shift

−31%

Consumer Complaints

Flat product complaints and over-carbonation burst incidents reduced in the 6-month post-deployment window

How Allie Works Here

From signal to action in real time.

Process ControlQuality ControlPredictive Maintenance

The Process Control agent monitors Anton Paar CO2 volume readings at 2-second intervals and applies a temperature-compensation model to predict actual dissolved CO2 at the filler bowl temperature. When the prediction indicates CO2 will be outside spec at the filler, the agent adjusts injection pressure setpoint via Comac OPC-UA interface 45–90 seconds upstream, correcting before the product reaches the fill zone. The Quality Control agent maintains a shift-level specification adherence score and correlates DO exceedances to specific upstream events such as tank breathing, pump cavitation signatures, or incomplete CIP rinse. The Predictive Maintenance agent monitors CO2 mass-flow meter drift and injection valve seat wear, prompting calibration or replacement through the Maintenance agent's work-order queue before drift translates into out-of-spec product.

Machines & Connectivity

OT-connected, protocol-native.

Comac Carbotek Carbonator

Comac

OPC-UA

Inline carbonation system injecting CO2 to volume spec before the filler bowl

Anton Paar CboxQC Inline Analyzer

Anton Paar

Modbus TCP

Real-time CO2 volume and dissolved oxygen measurement in the product stream

Schneider Electric Modicon M340 PLC

Schneider Electric

Modbus TCP

Controls CO2 injection valve, product temperature compensation, and interlock with filler permissive

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
CO2 Volume in Product	`CARB01.CO2.VOL`	vol CO2	3.2–4.1	3.6–3.8	Tighter
Dissolved Oxygen at Filler Inlet	`CARB01.DO.FIL`	ppb	60–120	≤40	Lower
Product Temperature at Carbonator	`CARB01.PROD.TMP`	°C	1.5–5.0	2.0–3.0	Tighter
CO2 Injection Pressure	`CARB01.CO2.PRES`	bar	3.8–5.2	4.2–4.6	Tighter

CO2 Volume in ProductTighter

CARB01.CO2.VOL

Baseline: 3.2–4.1 vol CO2→ 3.6–3.8 vol CO2

Dissolved Oxygen at Filler InletLower

CARB01.DO.FIL

Baseline: 60–120 ppb→ ≤40 ppb

Product Temperature at CarbonatorTighter

CARB01.PROD.TMP

Baseline: 1.5–5.0 °C→ 2.0–3.0 °C

CO2 Injection PressureTighter

CARB01.CO2.PRES

Baseline: 3.8–5.2 bar→ 4.2–4.6 bar

In the Field

"a carbonated beverage producer running inline mixer and filler on multiple high-speed lines, pilot targeted 50% waste reduction, generalizable across sister plants in the group"

Deployed at a carbonated beverage producer running inline mixer and filler on multiple high-speed lines, pilot targeted 50% waste reduction, generalizable across sister plants in the group. The results above reflect production data from the 60–90 day period following full deployment.

−74%co2 volume variance

−89%do exceedances

−31%consumer complaints

Next Step

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