Case Studies For Sanitary Process Systems for Wineries, Breweries, Milk, Dairy, Food, and Beverage Facilities
Challenging problems require creative solutions and that’s what we’re all about. From working with small start-ups to partnering with Fortune 500 companies like Nestle, Coca-Cola and Kraft, our successful projects and satisfied customers are what keep us from accepting the status quo. Check out some of our sample case studies to see how we manage a project from start to finish.
Our customer is expanding their manufacturing capability to offer co-packaging services for gluten-free sauces. A crucial element to packaging shelf-stable products is incorporating a kill-step or what is commonly called a pasteurizer or high-temperature short time (HTST) process. Our customer has a plan on what utility steam system to use. However, they hired Placer Process to design, fabricate, and install the liquid process pasteurization skid system.
Our customer is an innovative vegetable and fruit processing vegetable and fruit processing company who is developing modern methods of growing produce in a controlled environment. Rather than growing produce in the typical soil, the manufacture uses hydroponics and reusable trays for a more sustainable farming methods. The customer is currently using a conveyor system for a continuous cleaning during a full production shift. The system would need the ability to keep up with the cleaning-in-place demand.
Our customer is a leader in producing high quality and healthy single serving frozen meals. A key component to the flavor of the frozen meals are the sauces added during cooking or packaging. Due to the numerous types of frozen meals produced daily and the quantity of process lines needed to transfer the sauces to multiple points of use, the process of cleaning the process lines daily was a daunting and tedious task.
A manufacture of tomato-based sauces was producing in a typical method where the existing sanitary process used pipes that carried both ingredients, rinse waters, and CIP solutions depending on the time of the process cycle. The existing process did meet the requirements of all good sanitary design practices and produced an excellent product. However, the process through years of growth was relying on the use of jumper pipes and jumper panels.
Our customer is a premier producer of various spirits including wine. At a major wine producing and bottling facility located in San Joaquin County a new bottling line was being installed. A fundamental process for wine before bottling is filtration. Filtration of wine can enhance its appearance, shorten aging time, lighten color, make the wine more stable, and reduce the chance of re-fermentation while in the bottle.
Our customer is a premier supplier of ready-to-drink and milk products to the Western region of the United States. As with most beverage and dairy product manufacturers, a key component to the plant’s production capabilities is the ingredient storage capacity with a focus to unload waiting deliveries as quickly as possible to minimize potential demurrage charges.
Our customer is a leading manufacturer of cheese, whey protein, and other dairy ingredients. Maintaining a clean and sanitized production facility is vital to ensuring dairy products are safe for consumers and will have maximum shelf-life. Most sources of contamination come from outside the production facility and are brought in by various means such as articles of clothing, equipment, tools, etc. For our customer, there was a concern that bacteria from uncontrolled and unsanitary parts of their facility could harbor on personnel’s shoes and unknowingly be brought into sanitary production areas.
Our customer is a premiere supplier of milk and dairy products to the Western region of the United States. As market demands change, so do the product offerings our customer must be able to produce. Fruit in a yogurt cup is a type of product that is consistently consumed and is one of our customer’s primary product offerings. To keep a fresh spin on the fruit in a yogurt cup concept, new ways of presenting the fruit must be developed along with engineering new filling techniques to produce the new concepts. Filling and dosing systems were designed and fabricated to produce a new fruit in a cup concept for our customer that needed to be installed and integrated into their facility’s existing infrastructure.
Our customer is a leading manufacturer of dairy products including nonfat dry milk and skim milk powders. A key step in the milk drying process is to pre-heat the milk prior to entering the dryer using various types of heat exchangers. The type of heat exchanger our customer used to pre-heat their milk was a triple tube which required frequent servicing. Wear items, such as gaskets and seals, must be replaced to keep the heating medium from entering the product side of the tubes.
Our customer is a leader in producing high quality wines with small winery methods. A fundamental process for wine production is filtration. Filtration of wine can enhance its appearance, shorten aging time, lighten color, make the wine more stable, and reduce the chance of re-fermentation while in the bottle. Adding “polish” to a wine’s appearance is a choice many wine producers make.
Our customer is a leader in producing luxury wines of various varietals. A fundamental key to making a repeatable quality of wine at a consistent production rate is to ferment the wine at a defined and steady temperature. To do this most winemakers rely on the natural heat of fermentation and steady ambient temperatures. The issue is that harvest, crush, and fermentation can span for weeks which means the day and night ambient temperatures are likely to fluctuate resulting in an inconsistent quality of fermentation, thus, inconsistent quality of wine.
Our customer is a premiere supplier of milk and dairy products to the Northwest region of the United States. As the demand for their milk products increased due to population growth within their region, so did the need to expand their production capabilities. As with most dairy producers, and food manufacturers in general, our customer needed to increase production within their existing production plant by expanding its infrastructure and adding more fluid milk processing equipment.
Our customer is a premiere producer of various spirits including wine. At a major winery located in Monterey County, a combination of centrifuge separators and a diatomaceous earth press filter were used to clarify the wine after fermentation. As production demands and fermentation capacities grew, the winery’s filtration capacity was creating a production choke-point.
Fabricate components on a supporting frame including tanks, control panel, disconnect switches, valves, pump(s), instruments, and piping
High-end food and beverage equipment represents a significant investment in company resources. When changes occur — lines are shut down, processes are relocated, or consumer preferences change and equipment becomes obsolete — that once valuable equipment is no longer needed. This now seemingly useless equipment tends to either occupy precious space in a facility or get discarded. With companies and consumers becoming more environmentally and economically conscious, Placer Process Systems has developed a way to efficiently reuse equipment that is cost-effective and reduces lead time.system.
The quality of a beverage often depends on the size of its ingredients’ particles. Whether these are minute pieces or large chunks can be determined by the shear rate of mixing during production. Beverages such as sports drinks or vitamin waters made using powders are best manufactured with high speed mixers. In the case of pulpy formulations or drinks with high solids content, high sheer mixing can masticate ingredients, destroy consistency, and reduce the overall product quality.reduces lead time.system.
At every plant, water distribution demands change over time. New lines, new equipment, new products, and new processes lead to constant evolution. Sometimes the changes are incremental, other times they are dramatic and happen quickly. Often modifications are made to the water distribution without consideration being given to the entire water system. The absence of a master plan to coordinate changes can lead to distribution issues and peak demand can exceed capability.time.system.
A major carbonated beverage bottler was experiencing syrup loss and high change-over time. Their manual processes with extensive use of hoses also had the potential for operator exposure to CIP solutions and high temperatures. With material costs, efficiency, and operator safety on the line, the bottler turned to Placer Process for a solution.capability.time.system.
In most sanitary process designs, transfer lines must carry both ingredients and CIP solutions. A key component to any process design then becomes how to keep the two from commingling. So what is the best design to keep the ingredients and solutions apart, the lesser-expensive but labor-intensive transfer panels or automated mix proof valve clusters?em.
While upgrading a pasteurization system for a major beverage producer, we were asked to assist with water conservation efforts within the plant. The city water supply was restricted due to local water usage standards, which prevented the facility from running at full production capacity. The plant was also under strict sanitary drain limits, and regularly required third party water treatment services. After a succinct water usage audit, the concentrate reject stream from the nano-quality semi-permeable membrane system was identified as a major contributor to overall wastewater volume.proof valve clusters?em.