PROJECT

Hot Snack Line Debottlenecking

Our team provided front-end planning, early procurement and integrated design-build services to help a snack foods manufacturer debottleneck two hot snack lines in one facility. The evaluation resulted in production area air handling equipment changes to allow the lines to operate with extended runs. Fryers and extruders were replaced to increase capacity. Two packaging systems were renovated to support increased production rates by increasing accumulation capacity.

We also evaluated construction sequencing and timing with equipment deliveries, plant shutdowns, and outages to minimize disruption during project execution. Our project deliverables included design basis and purchase specs for the following components: fryers, heat exchangers, extruders, oil filters, ammonia cooled-air handling units, packaging and electrical equipment. We also led design of refrigeration system improvements, implemented process commissioning (Cx), equipment vendor expediting, final acceptance testing (FAT), final inspections and on-site vendor support.

Client

Confidential

Location

Midwest U.S.

Region

Midwest

Services

Industrial, Manufacturing & Optimization

Food & Beverage

Industry

Manufacturing & Industrial

Case Study

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Project responsibilities included:

Production area environmental changes. To extend run time between sanitation windows, the overall temperature of the production environment was lowered. Facility improvements included: five new rooftop units (RTUs), new process drains, updated flooring, a revised wall layout, roof penetrations and roof platforms to support the RTUs and exchangers. Additional enhancements were made to both the glycol and ammonia systems to improve overall efficiency and reliability.

Fryer replacement. Two new fryer systems were installed, each with all relevant elements of the fryer heating system and fryer support module, including infeed and discharge equipment and ancillary support items. Fryers had the longest procurement lead times, and our team assisted in development of a strategy supporting the overall project schedule.

Extrusion capacity. Extruders on line 1 were upsized to increase throughput. Supply and discharge elements around the extruders were evaluated and increased to support the added throughput.

Two upgraded production lines. Line additions included fryers, gas-fired heat exchangers, extruders, product conveyance, exhaust oil/air separation, and supporting unit operations.

Packaging systems. The project included several upgrades to packaging systems and facility infrastructure: new distribution conveyors connecting freezers to weighers, a new off-line packaging system and modifications to downstream packaging processes.