Aseptic Filling Line Installation and Facility Upgrade

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Location: Southern US

Our client hired POWER to assist with the installation of a new aseptic food line in one of their production facilities. The goal was to install an aseptic line with higher operating efficiency than the existing line.  POWER provided assistance with research, evaluating and choosing the best option for packaging downstream from the filler through palletizing, as well as engineering support for the process and infrastructure portions of the project.  To make the changes necessary, the project scope included new equipment installation, existing warehouse renovation, a building addition, and necessary utility and facility upgrades.

POWER was tasked with completing the front-end engineering required to help our client select the packaging option that met the goals of the project, developing P&ID drawings and equipment layouts, developing an overall building general arrangement, conducting a utility study, and identifying the controls, power and facility modifications required to support the installation of the new production line.  POWER developed six EPC (Engineer, Procure, and Construct) bid packages that encompassed the entire project scope in order for our client to solicit bids from selected vendors and contractors.

The project’s challenges included identifying the process and facility requirements for producing new products on this line that were not currently produced on any of their existing aseptic lines, finding a packaging solution that would result in increased operating efficiencies over their current production lines, and clearly delineating between the six different EPC bid packages that would be required to complete the project.  To resolve these issues, POWER conducted a thorough site investigation, which included interviews with the plant’s team members to identify performance expectations and to review lessons learned from previous installations.

POWER’S project solutions included development of packaging layouts that included accumulation equipment that our client had not previously considered.  Additionally, we performed a packaging line simulation to provide proof of the efficiency improvements of our proposed equipment.  POWER also developed a process area layout that included the installation of separate rooms and HVAC systems to provide the sanitation separation required to produce the new products.  POWER also developed a bid scope format that clearly delineated the six different EPC bid packages.