Fully Automated Canning Line

CEITM provided engineering services for the design and installation of a fully automated retort line for packaging of canned products. This automated design was fully comprehensive starting with empty cans and aseptic product, and ending with assembled pallets of labeled cans wrapped and ready for shipping. The final design and execution were based on CEI’s conceptual engineering design package which included block flow diagrams with mass balance to identify production requirements, flows, utilities, manpower, and overall process definition. This required multiple capital cost estimates and layout drawings to allow our customer to choose the best approach and optimum design for their company.

The project scope included renovation of an existing space, and designing new spaces for the new equipment. CEITM provided scope development services for this project to establish the improvements necessary to accommodate a fully automated retort line. These improvements included updating the IMP wall design, installing drains and electrical supply ports and site selection for a required cooling tower. This was a very successful project integrating all areas of process and utility design culminating in a valuable addition to our clients’ already impressive production capabilities.

Greenfield Potato Processing Plant

Greenfield Potato Processing Plant

In 2016 CEITM was selected as part of the design team for a new, state of the art, greenfield potato processing plant.  The total project budget was $250MM and included a 250,000 sq.ft. processing building, 43,000 sq.ft. receiving building and a wastewater facility.

CEITM provided preliminary and final design for the process support systems starting with P&ID’s to define details and scope definition.  AutoCAD Smart P&ID was used for a database of equipment and piping information issued to contractors for procurement.  In total, CEITM designed 11.3 miles of piping systems for steam, condensate, natural gas, compressed air, water and glycol.

The P&ID’s were the basis for equipment and piping design which were done in 3D and coordinated with the site and building design through shared models with a multidisciplinary design team for process, architectural, structural and civil details.  Weekly design meetings were held over WebEx to review progress and challenges via virtual walkthrough in Navisworks.  The 3D design was then “flattened” for dimensioned construction drawings with notes and specifications for installation contractors who utilized these drawings and the 3D model for direction.

Through innovative design, CEITM was able to provide this client with over $500,000 in capital cost savings and $500,000/year in operational natural gas savings.

CEITM Responsibilities

  • Process Heat Recovery Systems
  • Ammonia Refrigeration
  • Glycol System
  • Steam & Condensate
  • Natural Gas
  • Compressed Air
  • Water Systems
  • Drains and Underfloor Plumbing
  • Chemical Systems
  • Oil Systems
  • Solid Waste Handling
  • HVAC System Sanitation Systems
  • Safety Systems

 

 

 

Seafood Facility SQF Renovation

CEITM provided plant design and scope development services to incorporate SQF requirements into a seafood processing facility renovation project. The specified plant design created the necessary distinct production zones with physical separation, sloped floors, and a brand new plant layout in order to upgrade to SQF Level 2. CEITM contracted with the required architectural consultants and SQF auditors to ensure all work within scope was accomplished to the highest level of quality. This plant redesign included general arrangement and critical elevation drawings, a conceptual cost estimate (± 20%), a conceptual milestone schedule, and formal meeting minutes to amplify communication and organization. CEITM was able to create a clear path for our customer to follow in order to achieve SQF Level 2 Certification with the minimal amount of disruption to their existing process.

Jerky

CEITM  provided a broad spectrum of services to this meat jerky processor from engineering design to project management assistance in order to fully upgrade an existing processing line to a newer, more automated and efficient process. CEITM analyzed the existing jerky production facilities from receiving through packaging, and designed multiple upgrades for the client for minimal downtime of the existing operation. The processing line changes increased quality, improved sanitation, and reduced operating costs allowing the client to gain a competitive advantage in total cost per pound of product. The limited shutdown of the existing production operation during project installation was a key consideration for success of the project.

Critical aspects of this project included an accurate preliminary cost estimate, schedule, and block flow diagram with process mass balance during the initial design phase. CEITM evaluated critical design variables and created general design criteria for the quality of the systems required.

Extended Shelf Life Milk Filler

CEI™ provided process and packaging engineering services for the design, procurement and installation of a new Extended Shelf Life Filler in an existing milk plant with a total project budget of ~ $3.5MM.  This required detailed design work for 3A dairy processes as well as water, steam, compressed air, CIP systems, chemical systems, automated sanitary (mixproof) valves and controls specifications.  The client was extremely pleased with our methods of project execution and the final quality of the installation.  This project had a high degree of complexity as it required the addition of new equipment and systems to be integrated into existing buildings and processes that had no planned down time available.  Therefore, the design had to be segmented into 7 distinct phases with each phase designed for 24 – 48 hour installation periods over weekends and from midnight to 8 AM.  Our fees for preliminary design, final design, project management and construction support services were directly in line with the client’s budget, not including the unforeseen scope additions due to retrofit of an old building, floor / drain repairs, additional equipment systems added, and late addition controls upgrades.  CEI’s competitive bidding process saved the client approximately $513,000 which helped offset the project scope additions.

Brew House and Boiler Room

CEITM  provided process and utility engineering services for the analysis, design, and specification of equipment necessary to double the production capacity of a 30BBL brew house. This required an energy and mass balance of the production and packaging systems in order to assess which equipment would suffice or require replacement. In addition, the energy load of the existing and newly specified equipment was analyzed for necessary upgrades in the general utility design. This resulted in a full set of general arrangement drawings, detailed pipe routing drawings, and P&ID’s to aid the client in construction and startup of these new brew house additions. Our experienced assistance was key for the customer to remain on schedule, despite tackling some unexpected utility complications.

The client was so pleased with the thoroughness of our first project, they quickly commissioned our engineering services to provide stamped drawings for permit approval for the Boiler Room and Steam and condensate piping. We worked with the vendor to ensure all the necessary details were covered in order for the permit approval process to proceed smoothly the first time. In addition, we submitted a new propane design to upgrade the inadequate system in order to handle the increased load. CEI’s experienced design allowed both projects to proceed smoothly and handle the unexpected obstacles which occur on any project.

Dairy Pilot Plant

CEITM provided engineering services to aid in the development and installation of a major food processor’s pilot plant. This testing facility included a whey dryer, an HTST, NF/RO membrane systems, tanks, pumps, and other peripheral equipment all scaled down to testing batch size. This pilot plant included a full scale CIP skid responsible for cleaning all testing equipment to truly replicate the main processing facility.

This project required a full set of block flow and mass balance drawings, P&ID’s, and equipment layouts. CEITM collaborated with the architectural firm to optimize the testing facility building and space/area arrangements to work best for process design. This complex plant required trace circuit drawings for production and CIP circuits due to the highly flexible process design. This project successfully gave our customer a true to scale testing facility where future products will be imagined, created and tested.

White Wine Energy and Utilities

CEI™ was requested to assist with process support utility engineering for a new white wine production facility in Oregon.  The goal was to review, from an engineering basis, certain utility loads for the new white wine facility based on a typical vs. a “heavy” harvest schedule. The main areas analyzed for this system included:

  • Capacity of the existing boiler: could the unit handle the additional loads anticipated from the new facility.
  • Sizing the new chiller based on production schedules and environmental (spatial ventilation) requirements.
  • Architectural drawings for planned equipment layout and basic design.
  • Applicable general Utility Pipe routing and required drop points.

CEI™ sized a new chiller based on a model created to simulate the heat produced by wine fermentation within an entire cellar of stainless steel tanks and casks. This simulation allowed for more accurate energy modeling based on the crush data from past years. In addition, CEI™ analyzed the existing boiler to determine the available excess capacity, and if it would be sufficient to cover the new production needs.

General equipment location, process space requirements, and utility piping routing drawings were prepared to assist the contractor with the use of equipment procurement and development of installation scope documents. The equipment location drawing provides placement for air vents, exhaust fans, fluid coolers, humidifiers, and space heaters. In addition, CEI™ provided a piping schedule to the general contractor as a guideline for utility piping design.

 

 

Greenfield Brewery

CEITM provided process and utility engineering services for the analysis, design, and specification of equipment necessary for the installation of a New 92BBL Cast Out Brew House.  This project required a full set of block flow/mass balance drawings, P&ID’s, equipment layout and piping (including isometric) drawings. CEITM collaborated with the other engineering disciplines, Architectural/Structural and the construction firm to optimize the facility building and space/area design.

CEITM engineering services included: 

  • Managed the cost control for the entire project (Including building and process costs).
  • Provided specifications and procurement documents for the process installation.
  • Provided conceptual/preliminary engineering assistance for initial site layout options for an odd shaped property with limited space for growth plus options for future integrated growth as well.
  • Provided the process and mechanical installation drawings: P&ID’s, layout and piping drawings for the entire project.
  • Developed standards for the plant (Instruments, Valves).
  • Managed the process installation for, but not limited to, the following:
    • “Beer Bridge” across a city street that connected the existing plant with the new plant
    • Prepared purchase orders / contracts for the process systems:
      • 80,000 lbs. – Bulk malt storage
      • Specialty Malt Storage
      • Qty. 9 – 800BBL fermentation tanks
      • 92BBL (Cast Out Capacity) Brew House
      • Mill System
      • Disc chain conveyor delivery system
      • Utilities – two 150 lb. High Pressure Steam Boilers
      • Refrigeration System
      • Controls for the plant
      • Wastewater System
      • Bulk CO2 Storage and distribution
      • Sanitary process piping, including CO2 venting
      • Dust collection system
      • Separator (fermentation, cellar operations)
      • Catwalk (for fermenter tank access)
      • Pipe supports
      • Electrical Installation
      • Sanitary and Mechanical Piping
    • The process installation
    • Provided Startup support

Stillhouse Expansion, Energy and Utilities

A Distillery decided to move their existing distillation operation to a new location in Portland, OR while also expanding capacity by adding a new whisky still and brewhouse system.  CEITM was engaged by a design-build contractor to provide process and utility design for the stillhouse including mass balance, energy recovery, piping, ventilation requirements, HVAC, steam, compressed air, cooling systems and water systems (process, dechlorinated and deionized).

CEITM provided a unique cooling system design that allows the use of a cooling tower for very low cost cooling during cold months of the year that also included a “run dry” feature to save on water when outside temperatures and humidity are low enough that tower flow is not needed.  A backup glycol chilling system was designed to make up the remainder of the cooling as needed in warmer months.

A challenge with this project included a new, more stringent level of ventilation requirements for the alcohol production industry in Portland which required extraordinary venting calculations and mechanical requirements to obtain city permits.  CEITM was able to provide extensive and detailed stamped calculations to accompany the design for the City reviewers to understand and approve the design.  The shape of the building was also a challenge and the space allocated for utilities was only marginally big enough for proper clearances around equipment and some creative piping had to be done to fit everything into the space.