APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-017 · Engineering case
Led engineering integration of an automated ceramic-crossflow platform that replaced legacy disposable-media and hollow-fiber filtration.
Led engineering integration of an automated ceramic-crossflow platform that replaced legacy disposable-media and hollow-fiber filtration.
Coordinated installation and integration of the ceramic membrane ceramic-crossflow system, automated manifolds, CIP, carbon paths, stack filters, tank-level automation and utilities/controls.
Led engineering integration of an automated ceramic-crossflow platform that replaced legacy disposable-media and hollow-fiber filtration.
Workstream Portfolio Rollup
18,317,000 USD
Wine Clarification and Vinegar Polishing Modernization
Recorded workstream portfolio reference. This is the workstream-level value and is not a project expenditure or a new total of reassigned projects.
| Measure | Value | Type & meaning | Attribution & operating context |
|---|---|---|---|
| Operating Benefit | 229,000 USD/year | Actual Result Operating Benefit | Applies to: ceramic membrane ceramic-crossflow system integration Recorded ceramic-filtration OPEX reduction of approximately $229,000 per year. The related labor-cost measure and financial-option comparisons are separate analytical views of this project. |
| Volume | 31,520 GPD | Design Parameter Peak-demand design basis | Applies to: ceramic membrane ceramic-crossflow system integration Ceramic filtration demand support — 31,520 GPD peak-demand support basis for the ceramic filtration system. |
| Operating Measure | approximately 90 % | Baseline Vendor laboratory baseline | Applies to: Reviewed the vendor filterability study as a design baseline for ceramic filtration: membrane flux, pore size, clean-water-flux recovery after CIP and filtrate turbidity study, 2018 — after one CIP — Clean-water-flux recovery in the filtration supplier vendor study. |
| Turbidity | 0.26 to 0.39 NTU | Baseline Vendor laboratory baseline | Applies to: Reviewed the vendor filterability study as a design baseline for ceramic filtration: membrane flux, pore size, clean-water-flux recovery after CIP and filtrate turbidity study, 2018 — filtrate — Filtrate turbidity in the filtration supplier vendor study. |
| Membrane Flux | 138 L/m²/h | Baseline Vendor laboratory baseline | Applies to: Reviewed the vendor filterability study as a design baseline for ceramic filtration: membrane flux, pore size, clean-water-flux recovery after CIP and filtrate turbidity study, 2018 — Membrane flux — study, 2018 |
| Membrane Pore Size | 0.2 µm | Equipment Rating Vendor laboratory membrane specification | Applies to: Reviewed the vendor filterability study as a design baseline for ceramic filtration: membrane flux, pore size, clean-water-flux recovery after CIP and filtrate turbidity study, 2018 — Membrane pore size — study, 2018 |
31,520 GPD peak-demand design basis.
Approximately 90% flux recovery in the separate 2018 laboratory baseline.
Less than 0.4 NTU turbidity in the separate 2018 laboratory baseline.
Peak-demand design basis: 31,520 GPD. The separate 2018 laboratory baseline reported approximately 90% flux recovery and less than 0.4 NTU turbidity. The system records approximately $229,000/year OPEX reduction.
Sanitary filtration and polishing boundary. ceramic membrane records cover crossflow filtration, flow and transmembrane-pressure control, product recovery, backflush, time-based chemical dosing, heated caustic circulation, cooling, final-water flush, and automatic sequence control. The ceramic-system audit documents loose sanitary clamps, gasket failure in nitric service, dirty filters, logging gaps, corrective cleaning, SOP changes, and continuing PM and inventory needs.
Aseptic-practice requirements include sanitary valves and sample ports, hygienic purge-gas quality when used, closed transfer, drainability, filter and membrane integrity acceptance, defined cleaning time-temperature-concentration-flow parameters, rinse endpoints, idle-system protection, time-limited clean holds, controlled recovered-product routing, ion-exchange regeneration and rinse release, including turbidity and microbiological release criteria, and deviation response for breakthrough or contamination.
Sanitary recovery and environmental boundary. A5 planning records cover scrubber equipment, scrubber water routed to holding tanks, filtration or ultrafiltration, tank-farm piping, wastewater drainage, air permitting, water-use permit modification, and source testing. Membrane evidence adds product-recovery, rinse, and cleaning-effluent sequences. Product, reusable water, condensate, wastewater, chemical waste, air or vapor, and biologically active waste are treated as distinct physical and control states.
Food and Beverage Manufacturer
Owned the full project lifecycle, from capital planning through commissioning and post-startup support. Filtration performance depended on the entire cleaning and product-flow cycle.
TSK-000037 · Method
Ceramic Filter CIP Interface Engineering
ACTIVITIES IN CONTEXT
TSK-000035 · Method
Ceramic Membrane Ceramic-Crossflow System Integration
TSK-001008 · Vendor study context
Ceramic Membrane Ceramic-Crossflow System Integration
Full lifecycle project ownership
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Project Reference Context
Reference Context
Filtration supplier performed the 2018 filterability study used as a membrane-performance design baseline; those laboratory results are separate at the facility commercial operation.
31,520 GPD peak-demand support and approximately $229,000/year commercial OPEX reduction. The 90% flux-recovery and 0.26–0.39 NTU observations belong to the separate 2018 filtration supplier vendor study.
The Food Safety sheet of Equipment Purchase and Installation Safety Checklist.xlsx records engineering review/signoff by for ceramic membrane Crossflow 17.42, the feed manifold, the permeate manifold and Freshwater Tank V-56 in the Bulk / Drumming Warehouse. This adds installation-review scope, not sterile-process certification.
Coordinated ceramic-crossflow architecture, TMP and flow control, backflush, product recovery, timed chemical dosing, heated caustic circulation, cooling, rinsing, automated sequences, utilities, and controls.
31,520 GPD peak-demand support.
Approximately $229,000/year OPEX reduction.
The filtration supplier system architecture describes: Chemical tanks: TK-B5 HYPO 200 L, TK-B3 CAUSTIC 200 L, TK-B4 ACID 200 L.
The filtration supplier system architecture describes: Feed/circulation tank TK-01: 820 L.
The filtration supplier system architecture describes: Permeate/backflush tank T2: 100 L.
The filtration supplier system architecture describes: ceramic membrane module M0001; heat exchanger HE30; pumps P01, P02, P03, and chemical pump P80.
The filtration supplier system architecture describes: P&ID labels STEAM 1 BARG; CP-07 condensate callout includes 1-2 barg and 1.500 litros/hora; another 1.500 litros/hora callout appears near CP-09 retentate recovery.
The filtration supplier system architecture describes: Slide 2: concentrate-side tag group 01-19; TK01 as feed buffer/circulation tank; P01 controls FIT11; lower/higher circulation changes loop-to-tank concentration relationship; CV08 controls PIT01; P02 provides approximately 5 m/s crossflow.
The filtration supplier system architecture describes: Slide 3: permeate/backflush tag group 50-59; FCV01.1 controls flow or TMP; P03 sends filtrate to final tank and backflushes; AV51/56 close during backflush; T2 backflush volume is deducted from filtrate and returns to TK01.
The filtration supplier system architecture describes: Slide 4: chemical tags 80-89; chemical dosing by time; each dose followed by AV82/AV89 water flush; utility group stated as 30 to 29, an internal source error; temperature uses minimum/maximum hysteresis.
The filtration supplier system architecture describes: Slide 5: source calls system totally automatic with low operator intervention; skid exchanges requests/confirmations with peripheral equipment but explicitly does not control the peripheral plant.
The filtration supplier system operating description records: Slide 6: workstream hierarchy includes start/play, steps, phases, auxiliary sub-phases, stop, and end-of-workstream logic.
The filtration supplier system operating description records: Slide 7: production sequence starts full of water, then forced/gravity drains on permeate and concentrate sides, TK01 raw-vinegar fill, concentrate/permeate fill, filtration/concentration, final concentration, permeate/concentrate recovery, and cold-water rinse.
The filtration supplier system operating description records: Slide 8: system full-of-water starting state.
The filtration supplier system operating description records: Slide 9: forced permeate drain uses AV56/76/54/65, FCV01.1 at 100 percent, P03 at 50 percent; ends by maximum time, T2 minimum level, or LSL-02.
The filtration supplier system operating description records: Slide 10: gravity permeate drain adds AV58, FCV01.1 at 100 percent, P03 off; ends after LSL-02 delay.
The filtration supplier system operating description records: Slide 11: forced concentrate drain uses AV03/01/62, P01 at 50 percent; ends by maximum time, TK01 minimum, or LSL-01.
The filtration supplier system operating description records: Slide 12: gravity concentrate drain uses AV03/01/62/05/04, CV08 at 100 percent, P01 off; ends after LSL-01 delay.
The filtration supplier system operating description records: Slide 13: fill TK01 with product using AV11/03; ends at TK01 level setpoint.
The filtration supplier system operating description records: Slide 14: fill concentrate side using AV03/01/05, CV08 at 20 percent, P01 at 50 percent; ends when TK01 level stops changing.
The filtration supplier system operating description records: Slide 15: concentrate circulation uses AV03/01, CV08 at 20 percent, P01 at 50 percent and P02; ends by time delay.
The filtration supplier system operating description records: Slide 16: fill permeate side using AV03/01/56, CV08 at 20 percent, FCV01.1 at 10 percent, P01 at 50 percent and P02; ends at T2 level setpoint.
The filtration supplier system operating description records: Slide 17: filtration uses AV03/01/56/51, CV08, FCV01.1, P01/P02/P03; P01 controlled by FIT11; P03 by LIT02; CV08 by PIT01; FCV01.1 starts on FIT01.1 then switches to pressure control at TMP setpoint.
The filtration supplier system operating description records: Slide 18: low LIT01 opens AV11; high setpoint closes AV11.
The filtration supplier system operating description records: Slide 19: P02/circulation heats product; high TT02 opens AV32/34 cooling; low TT02 closes AV32/34.
The filtration supplier system operating description records: Slide 20: timed production backflush closes AV51 and stops P03; T2 fills high; AV56/FCV01.1 close; P03 approximately 100 percent; after approximately 5 seconds AV58 opens and consumes almost all T2; filtration resumes.
The filtration supplier system operating description records: Slide 21: filtration ends on maximum time/volume, maximum DPM PIT02-PIT01, maximum TMP, maximum TT02, minimum flow in TMP control indicating clogged membrane, or minimum flow with low TK01 and AV11 open indicating empty customer feed tank.
The filtration supplier system operating description records: Slide 22: final-concentration purpose is to limit final loss to loop volume.
The filtration supplier system operating description records: Slide 23: final concentration ends on TK01 low-low, maximum time, maximum DPM/TMP/temperature, or minimum filtration flow.
The filtration supplier system operating description records: Slide 24: permeate recovery uses AV56/54/51/76, FCV01.1, P03 fixed speed; ends by maximum time, T2 minimum, or LSL-02.
The filtration supplier system operating description records: Slide 25: concentrate recovery uses AV03/04/05/08, CV08, and source text says P03 fixed speed; end references LSL-01 at P01 suction.
The filtration supplier system operating description records: Slide 26: cold-water rinse fills feed/concentrate/permeate, circulates concentrate/permeate, performs forced/gravity drains, refills, and shows Repeat x2 with visually ambiguous bracket scope.
The filtration supplier system operating description records: Slide 27: cold-water fill TK01 via AV71; ends at TK01 setpoint.
The filtration supplier system operating description records: Slide 28: cold-water concentrate fill uses AV03/01/05, CV08 20 percent, P01 50 percent; ends when TK01 level stops changing.
The filtration supplier system operating description records: Slide 29: cold-water permeate fill uses AV03/01/56, FCV01.1 10 percent, P01 50 percent; ends at T2 setpoint.
The filtration supplier system operating description records: Slide 30: cold-water concentrate circulation uses AV03/01, CV08 30 percent, P01 50 percent and P02; time-delay end.
The filtration supplier system operating description records: Slide 31: cold-water permeate circulation uses AV03/01/59, CV08 30 percent, P01 50 percent and P02; time-delay end.
The filtration supplier system operating description records: Slide 32: cold-water backflush closes AV59; T2 fills high; AV76/FCV01.1 close; P03 approximately 100 percent; after approximately 5 seconds AV58 opens; AV59 reopens.
The filtration supplier system operating description records: Slide 33: TK01 flush fills T2 high, closes AV76/FCV01.1, runs P03 approximately 50 percent, waits approximately 5 seconds, opens AV70/77, and consumes almost all T2.
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Compared filtration options against demand and lifecycle requirements, integrated CIP and instrumentation with dedicated electrical feeds, and developed clean-water-flux tracking and maintenance follow-up. Ion-exchange testing extended the investigation into product clarity and quality, while modular expansion planning connected the equipment choice with future operating demand.
