Overview
In high-throughput beverage bottling environments, maintaining consistent line performance while undergoing frequent washdowns presents a unique challenge for industrial HMI systems. A regional manufacturer faced recurring disruptions caused by moisture, condensation, and unreliable operator interfaces on aging equipment. By deploying Premio’s SIO-300-ASL Series stainless steel panel PC, the facility introduced a washdown-ready HMI solution designed to maintain stable operation through sanitation cycles and high-speed production demands.
Challenges
- HMI latency during active production impacting operator response and line adjustments
- Frequent high-pressure washdowns triggering unintended touchscreen inputs and operational disruptions
- Internal condensation forming inside sealed systems due to pressure and temperature changes during sanitation
- Continuous vibration from filling and capping equipment affecting stability of machine-mounted systems
- Aging panel PCs creating inconsistent performance across production lines and increasing maintenance complexity
Solution
- Premio’s stainless steel panel PC (SIO-300-ASL Series)
- Intel Atom x7000 series processor for responsive, real-time HMI performance
- IP66 and IP69K sealed stainless steel enclosure for washdown durability
- Integrated pressure valve to equalize internal pressure and reduce condensation
- Native touchscreen enable and disable control to prevent unintended input during cleaning
Benefits
- Stable HMI operation during washdown cycles
- Reduced system failures from condensation and moisture
- Improved operator efficiency with responsive controls
Company Overview
A regional beverage manufacturer produces a wide range of bottled products for both local and national distribution. The company operates high-speed filling, capping, and labeling lines that require continuous uptime and strict sanitation compliance. As production complexity increases, the organization continues to modernize its automation infrastructure to ensure consistent performance across all lines.
The Challenges
Delayed Operator Response During Production
Operators experienced noticeable lag when interacting with legacy HMI systems, particularly during high-speed production runs. Adjustments to fill levels, conveyor speeds, and alarm acknowledgments were not reflected immediately, slowing response time. This created inefficiencies during peak demand and frequent product changeovers.
Unintended Touch Inputs During Washdowns
During daily sanitation, high-pressure water spray repeatedly activated the touchscreen interface. This resulted in unintended inputs, screen interruptions, and occasional disruption to active HMI sessions. Operators were forced to avoid interaction during cleaning, reducing visibility into real-time system status.
Condensation Inside Sealed Systems
Temperature shifts between production and cleaning cycles created pressure differentials inside sealed enclosures. Over time, this led to condensation forming behind displays and within internal components. The issue affected visibility and raised concerns about long-term system reliability.
Mechanical Stress from Machine-Mounted Deployment
Panel PCs were installed directly onto filling and capping equipment where continuous vibration is present. Over time, this mechanical stress affected mounting stability and internal components. The environment required a system designed specifically for sustained machine-level deployment.
Inconsistent Performance Across Production Lines
Different generations of HMI hardware across multiple lines created inconsistency in performance and usability. Operators had to adapt to varying system behaviors, while maintenance teams faced increased complexity supporting mixed hardware. Standardization became necessary to improve efficiency.
The Solution
Industrial HMI Deployment with SIO-300-ASL Series
Premio’s SIO-300-ASL Series was deployed across bottling lines at key operator touchpoints, including filling and capping stations. Powered by Intel Atom x7000 series processors, the system provides efficient performance for real-time visualization and control. This enables faster response during active production and reduces operator delays.
Washdown-Ready Stainless Steel Design
The system features a sealed stainless steel enclosure with IP66 and IP69K protection, allowing it to withstand high-pressure, high-temperature washdowns. It remains fully operational during sanitation without requiring removal or additional protection. The enclosure is constructed from corrosion-resistant stainless steel suited for hygienic environments .
Pressure Valve for Condensation Control
An integrated pressure valve equalizes internal pressure during rapid temperature changes. This prevents moisture buildup inside the enclosure, maintaining display clarity and protecting internal components. It directly addresses condensation issues commonly found in sealed systems exposed to frequent washdowns .
Touchscreen Disable Function for Cleaning Cycles
The system includes a built-in touchscreen enable and disable control that allows operators to deactivate input during washdowns. This prevents unintended screen activation caused by water spray while keeping the display active for monitoring. Operators can safely observe system status without interfering with ongoing processes .
Rugged Design for Machine Integration
Designed for direct mounting, the panel PC operates reliably on vibrating equipment such as filling and capping systems. Its fanless architecture and industrial construction support continuous operation under mechanical stress. This ensures long-term stability at the machine level.
The Benefits
Continuous Operation During Washdowns
The system remains fully functional throughout cleaning cycles, eliminating interruptions and maintaining visibility for operators.
Improved Long-Term Reliability
Condensation control and sealed design reduce failure points associated with moisture and environmental stress.
Streamlined Operator Experience
Responsive performance and consistent interfaces improve usability across production lines and reduce operator error.
Conclusion
By implementing the SIO-300-ASL Series, the manufacturer resolved critical issues affecting HMI reliability in washdown environments. The solution enables stable operation during both production and sanitation, while addressing real-world challenges such as unintended inputs and internal condensation. This upgrade supports more consistent, efficient bottling operations moving forward.