In the 2003 film “Finding Nemo,” clownfish Marlin embarks on a quest to find his son, who was taken by divers. Marlin encounters several characters along his journey to reunite with his son, including sharks, sea turtles and, most notably, a forgetful blue tang fish named Dory. Each of these characters aids Marlin in their own way, and he is eventually reunited with Nemo.

In the beverage world, processing operations are aiding beverage-makers as new age beverage trends are altering the formulation process.

Tom Lex, vice president and general manager of TechniBlend, Waukesha, Wis., explains that automation has elevated beverage processing operations.

“Automation has revolutionized beverage processing by improving efficiency, consistency and scalability,” he says. “Automated systems optimize production throughput by reducing manual intervention, minimizing human error and enabling precise control of critical parameters like temperature, flow rate and pressure.”

Moreover, Lex notes that automation supports real-time monitoring, predictive maintenance and traceability, all of which he considers to be essential for meeting stringent regulatory standards and maintaining product quality.

“Overall, these advancements lead to reduced operational costs and faster response times to changes in production demands,” Lex adds.

Brian Pascoe, vice president of business development, food and beverage at The EOSYS Group, Nashville, Tenn., echoes similar sentiments.

“Automation has significantly improved beverage processing by enhancing efficiency, consistency and data-driven decision-making,” Pascoe states. “While the fundamental principles of automation in beverage manufacturing have remained stable, technological advancements continue to drive meaningful improvements. Innovations in connectivity, control systems and data analytics now allow manufacturers to optimize operations with real-time insights, predictive maintenances and tighter quality control.”

These continuous improvements have led to increased productivity and reduced downtime, Pascoe adds, ensuring that manufacturers can meet evolving market demands more effectively.

Many trends have impacted operations within the beverage industry. Specifically, fortification has influenced mixing and blending equipment.

“The rise in fortified beverages, including those enriched with vitamins, minerals, probiotics and other functional ingredients, has increased the demand for precise and adaptable mixing and blending technologies,” TechniBlend’s Lex states. “These formulations often require delicate handling to ensure even dispersion and stability without compromising ingredient efficiency. Equipment needs to support gentle agitation, micro-dosing capabilities and compatibility with a wide variety of additives.”

Clean-in-place (CIP) features also are critical for maintaining hygiene when switching between formulations, he adds.

EOSYS’ Pascoe explains that the company operates as a system integrator. Its role begins once a client has defined their recipes and ingredient formulations, focusing on designing and implementing automation systems that precisely execute these formulations to ensure accuracy, efficiency and scalability, he says.

“Our solutions are ingredient-agnostic — if a process requires a specified amount of an ingredient, our automation system ensures that requirement is met without regard to the specific type,” Pascoe explains. “We collaborate closely with clients to fine-tune automation processes to meet performance and quality expectations.”

Alternative sweetener trends also have impacted processing automation.

The shift toward such sweeteners, like stevia, monk fruit and allulose, has introduced unique challenges and opportunities in processing automation, TechniBlend’s Lex says.

“These sweeteners often require precise handling due to their concentration, solubility differences and potential interactions with other ingredients,” he explains. “Automation has evolved to enable accurate dosing, advanced mixing technologies and real-time quality control to maintain consistency and uniformity. Additionally, modular systems allow manufacturers to adapt quickly to formulation changes driven by consumer demand, ensuring flexibility without compromising efficiency.”

 Lex lists the following as additional trends affecting processing equipment:

• Sustainability: Equipment is being designed to minimize water and energy consumption while reducing waste, aligning with environmental goals.
• Functional beverages: The rise of beverages with added health benefits requires precision in handling ingredients like adaptogens, botanicals and probiotics.
• Customization: Small batch sizes and the ability to produce diverse SKUs demand agile and scalable equipment.
• Premiumization: High-quality, minimally processed beverages are prompting investments in technologies that preserve ingredient integrity, such as high-pressure processing (HPP).
• Plant-based and non-alcohol drinks: These growing segments require equipment capable of managing unique viscosities, particle inclusions and clean-label formulations.

EOSYS’ Pascoe notes a trend in how manufacturers are optimizing and fine-tuning their existing processes, rather than making significant changes in processing equipment.

“One key trend is the increased adoption of servo-controlled systems for enhanced precision, repeatability and efficiency in automation,” he says. “Additionally, data integration and analytics tools are playing a larger role, allowing manufacturers to optimize batch consistency, reduce waste and improve overall equipment effectiveness (OEE).”

Making the move

Before investing in mixing and blending equipment, beverage-makers should take into account their situation. Techniblend’s Lex says several factors need to be considered, with the first being product versatility to “ensure the equipment can handle a range of formulations, including complex or sensitive ingredients,” he states.

Scalability, automation and integration are other considerations. Beverage-makers should “opt for systems that can grow with production needs,” Lex says. Equipment should be chosen based on which advanced automation features will integrate most seamlessly with existing production lines, he adds.

Lex also notes that CIP capabilities are essential for maintaining hygiene and reducing downtime.

Sustainability is another big factor. Lex urges companies to search for systems that support energy and water efficiency. He suggests that beverage-makers assess the upfront costs against potential savings in labor, energy and production efficiency.

The final factor to consider, according to Lex, is that of regulatory compliance.

“Equipment should meet industry standards for food and beverage safety,” he says.

EOSYS’ Pascoe states that, when investing in automation, it is critical for manufacturers to consider the compatibility of their chosen system with their in-house technical expertise.

“For example, if a plant’s maintenance team is highly experienced with one system or platform but selects on alternate system, it may face efficiency and support challenges,” Pascoe explains. “We help clients navigate these decisions, ensuring their automation investments align with their operational needs and workforce capabilities.”

As for the future of processing automation, Techniblend’s Lex anticipates that it will be “defined by greater connectivity, intelligence and sustainability.”

“Automation will increasingly leverage [Internet of Things] (IoT) and [artificial intelligence] (AI) to enable predictive maintenance, real-time monitoring and optimization of production processes,” he says.

Lex predicts that advanced analytics and sustainable automation also will take on larger roles.

“Data-driven insights will allow for precise control over variables like ingredient ratios, reducing waste and improving quality,” he explains. “Innovations will focus on reducing energy and resource consumption through technologies like regenerative systems and energy-efficient components.”

EOSYS’ Pascoe also predicts that AI and advanced automation technologies will bring significant changes to manufacturing.

“While AI has the potential to enhance efficiency, reduce labor dependency and improve data utilization, its best implementation strategies are still evolving,” he says. “EOSYS is already leveraging process simulation and emulation to optimize system performance before deployment.”

The company’s approach focuses on dynamic process simulation, Pascoe shares, which allows it to replicate real-world system behavior, identify potential issues and refine automation strategies before installation.

“These advancements reduce commissioning time, enhance system reliability and provide clients with greater confidence in their automation investments,” he concludes. “As manufacturing continues to evolve, EOSYS remains committed to delivering cutting-edge automation solutions that drive efficiency, adaptability and long-term success for beverage producers.”