While conducting product and process research in a university laboratory, this innovative client identified a new technique for processing aseptic and hot fill fruits and vegetables. They contacted POWER to assist them in the commercialization of their proprietary technique.
Supporting them from the facility master planning and site selection phases through final design, POWER provided engineering assistance in identifying and evaluating possible building locations, existing building acceptance studies, demolition plans, and full reconstruction and installation services including building, utilities, process, packaging, automation and controls. The final products included fresh fruit purees, mixers, and sauces.
Ultimately, the project entailed the conversion of a facility previously used for chicken processing into a state-of-the-art aseptic and hot fill processing plant. The facility included two lines that were designed to operate independently without limitation. The first line was a hot fill line processing and packaging fruit products into individual serving size retail pouches. The second was an aseptic line for cold filling products such as purees, soups, and sauces into multi-serve cartons.
- Cost savings achieved via master planning and careful site selection: Even though the selected site required extensive renovation, careful planning and thoughtful design allowed us to deliver the client with a state-of-the-art facility for less than the cost of a greenfield plant.
- Innovative design allowed reuse of existing equipment: While the original mechanical design eliminated the need for several room chillers that had been part of the original chicken processing facility, our team was able to reuse this equipment in the fruit and beverage prep areas, reducing the number of units the owner needed to purchase.
- Creative re-use of space maximized building footprint: Our team installed new mechanical systems (boiler, chiller, and HVAC) in a repurposed drive-in waste trailer loading room. The room, now used exclusively for process utilities was fully enclosed as part of the remodel.
- Smart design maximized existing electrical resources: By replacing an existing pad-mounted transformer on the plant electrical service with a larger transformer, our team was able to maximize the full potential of the existing service available at the main distribution panel.
- Equipment sourced from various venues delivered our client the best overall value: By leveraging a mix of used equipment, vendor systems, and new equipment, we were able to deliver a fully-integrated process system that met the project’s needs while paying close attention to the client’s budget.
- Conversion of an old chicken processing facility into a state-of-the-art, highly sanitary aseptic and hot fill juice processing and packaging facility
- Complete process system from fruit receiving, storage, and cleaning through mixing, blending, heating and cooling, hot fill and aseptic filling, packaging and finished goods warehousing
- Packaging system comprised of a manual loading system with automatic box formers, weight control, metal detection, and case tapers.
- New boiler, chiller, and HVAC systems
- Modification of main electrical service entrance to provide adequate distribution for new equipment
- Re-use of existing power panels (as available) paired with new power distribution panels and new pad-mounted transformer to support individual equipment loads.
- Modification and retrofit of an existing MCC with new sections and feeder buckets to provide correct circuit breaker sizing to new equipment
- New cable trays added above walk-on ceiling to distribute power feeders to new equipment locations
- Six new line control PLC and motor control panels
- Dedicated PanelView Plus 1000 supplied and programmed for each of the two lines
- Estimating services for the following:
- Building size requirements
- Process and packaging equipment needs (suitability for products, etc.)
- Raw ingredient requirements
- Product and personnel flow through the facility
- Site requirements
- Cost estimate for completed project
- Development of a final master planning report and conceptual drawings
Site evaluation and selection
- Evaluation and recommendations related to several possible sites/buildings, including recommendations related to:
- Available space
- Layout options
- Hygienic redesign requirements
- Traffic patterns
- Architectural modifications to facility Structural evaluation to determine acceptable roof loading Refurbishment and upgrade of the building’s mechanical facilities Process and packaging room layouts Electrical system overhaul to support new processing equipment
Process and packaging design services
- Process flow diagrams incorporating mass balance information
- P&IDs to show flow and control
- Plant flow diagrams
- General arrangement and equipment installation drawings
- Equipment lists with detailed utility information
- Room criteria matrices for all areas of the plant
- Equipment specifications
- Equipment selection and integration services
Automation and controls support
- Complete automation and controls support for two separate processing lines
- Design and supply of six new line control PLC and motor control panels
- Definition of the plant’s process control network and its interaction with the facility’s business network
- Configuration of the owner-supplied FactoryTalk historian to record critical process parameters
- Factory Acceptance Testing (FAT) support
- Vendor integration services
- Start-up services