APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-028 · Engineering case
Coordinated ceramic filtration into plant electrical and OT controls infrastructure with dedicated feeds, Ethernet connectivity, tank sensing, valve control, and CIP automation.
The ceramic filter project needed more than mechanical filtration equipment; it required robust electrical feeds, network connectivity, remote sensor wiring, automated valve blocks, and chemical/CIP control paths.
Design scope: 480V 750A ceramic filter main feed, 480V 4kW manifold feeds, 150A boiler coordination, Ethernet-based control connectivity through the fiberoptic OT network, tank level sensors with two-wire terminations, conduit runs from UF-F and tanks 19, 23, 27, 28, and 30, automated selection and cleaning sequences, solenoid block valves, leak-detection isolation paths, and steam / nitric / caustic CIP dosing.
Improved filtration automation, controls visibility, and CIP readiness.
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 |
|---|---|---|---|
| Electrical Power | 4 kW | Design Parameter Electrical design specification | Applies to: Ceramic Filter Electrical and Controls Coordination Ceramic-filter manifold electrical construction firm — Specified 4 kW manifold feed in the 480 V electrical design; not measured energy consumption. |
| Time | < 5 minutes | Observation Recorded operator interaction | Applies to: Ceramic Filter Electrical and Controls Coordination Ceramic filtration automated operation — Recorded operator interaction of less than 5 minutes per shift in the automation context. |
Improved filtration automation, operator interaction, CIP readiness, leak isolation, and process visibility.
Designed 480V 750A ceramic filter main feed, 480V 4kW manifold feeds, 150A boiler coordination, Ethernet-based control connectivity through the fiberoptic OT network, tank level sensors with two-wire terminations, conduit runs from UF-F and tanks 19, 23, 27, 28, and 30, automated selection and cleaning sequences, solenoid block valves, leak-detection isolation paths, and steam / nitric / caustic CIP dosing.
Improved ceramic filtration automation readiness, measured by a 480V 750A main feed, 480V 4kW manifold feeds, 150A boiler coordination, tank-level wiring across UF-F, 19, 23, 27, 28, and 30, and less than 5 minutes operator interaction per shift, by coordinating power, OT connectivity, sensors, valves, leak isolation, and CIP dosing.
750A main feed; 4kW manifold feeds; 150A boiler coordination; UF-F / 19 / 23 / 27 / 28 / 30 tank sensors; <5 minutes operator interaction.
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-000035 · Method
Ceramic Membrane Ceramic-Crossflow System Integration
TSK-000036 · Method
Filtration Demand and Capacity Modeling
TSK-000037 · Method
Ceramic Filter CIP Interface Engineering
Application context. Can product-contact paths be cleaned, segregated and operated within their hygienic scope?
TSK-000038 · Method
Ceramic Filtration Cost-per-Gallon and NPV Model
TSK-000039 · Method
Ceramic Crossflow Option Comparison and AFE Clarification
TSK-000040 · Method
Carbon-Treated Vinegar Prefilter and Fouling Prevention
Application context. Are cleaning states, chemistry, flow and release logic mutually consistent?
TSK-000041 · Method
Automated Infeed / Permeate Manifold and Vinegar Path Segregation
TSK-000042 · Method
Ceramic Filtration Sustainability and Operator Exposure Reduction
TSK-000043 · Method
Ceramic Filtration Labor-Cost Reduction
TSK-000044 · Method
Ceramic Filtration Modular Expansion Strategy
TSK-000062 · Action
Ceramic-Filter SOP, Preventive-Maintenance and CIP Audit
Application context. Do flow, pressure, materials and connection details satisfy the process duty?
TSK-000063 · Method
Ceramic-Filter SOP, Preventive-Maintenance and CIP Audit
TSK-000086 · Technical context
Ceramic Crossflow Filter System + Ion Exchange Trial
TSK-000856 · Action
Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded applicationTSK-000857 · Action
Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded applicationTSK-000858 · Action
Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded application
Design parameter · Vendor test proposal
Applies to: Coordinated and reviewed filtration supplier's laboratory cleanability study, using the vendor's neutralization, temperature and particulate findings to inform a production-validation decision
Proposed input — Proposed concentrate sample volume
Design parameter · Vendor laboratory test condition
Applies to: Filtration supplier tested dilute sodium-hydroxide neutralization of residual acetic acid at laboratory scale; the study found no identified crystal-like particulate and recommended production validation
Acid sample — Acetic acid sample volume — Acid sample
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.
Observation · Field observation
Applies to: Captured a complete ceramic-CIP waste stream, organized repeated multi-point sampling, and coordinated the wastewater receiver, internal stakeholders, filtration supplier and laboratories
Ceramic-CIP flush — CIP flush volume — Ceramic-CIP flush
Operating control · Receiver criterion
Applies to: Developed temporary containment and dilution measures and evaluated permanent alternatives against receiving-facility hydraulic, pH and sodium criteria
Receiving facility — Wastewater flow — Receiving facility
TSK-001011 · Action
Ceramic Crossflow Filter System + Ion Exchange Trial
Observation · Bench observation
Applies to: Compared the bench-test acidity, transmittance, color and turbidity results to evaluate decolorization and product effects
WDV — Before treatment — Acidity — WDV — Before treatment
TSK-001013 · Study design
Ceramic Crossflow Filter System + Ion Exchange Trial
Application context. Which formulation factors change functionality and manufacturing compatibility?
Scope or inventory quantity · Analysis scope
Applies to: Developed exploratory bed-volume, column, pump, batch and resin calculations; identified formula-error cells for correction before final sizing
Exploratory sizing — Sizing workbook sheets — Exploratory sizing
TSK-001015 · Control
Ceramic Crossflow Filter System + Ion Exchange Trial
Action
Applies capabilities
ACTIVITIES IN CONTEXT
TSK-000046 · Action
Ceramic Filter Electrical and Controls Coordination
TSK-000047 · Method
Ceramic Filter Electrical and Controls Coordination
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.
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.
