APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-058 · Engineering case
Led the Line 1 filler-valve and product-return retrofit to reduce contamination risk, stabilize product handling and improve high-speed filling performance.
The work addressed aging filler valves, O-ring and metal-to-metal contamination risk, unstable return flow, foaming, product spillover, and feed-rate limitations rather than functioning as a simple replacement.
Coordination scope: 44 self-sealing filler valves; custom slide ring assembly; upper and lower manifolds; cam ring/ramp; guide rods; rollers; return tank; return pump; level probes; sensor; pump-down relay; contactors; MCPBs; PLC-to-starter wiring; sanitary pump; vendor startup and training.
Reduced contamination risk, foaming, leaking, spraying, and filler reliability exposure.
Workstream Portfolio Rollup
28,095,000 USD
Production and Packaging 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 |
|---|---|---|---|
| Filler Feed Capability | >= 85 GPM | Equipment Rating Equipment capability | Applies to: Line 1 Filler Valve and Product Return Upgrade >=85 GPM feed capability |
| 64 Oz Filling Throughput | 120 BPM | Observation Recorded SKU filling rate | Applies to: Line 1 Filler Valve and Product Return Upgrade Portfolio-reported SKU filling rate in the Line 1 filler case; no before/after rate comparison is supplied for this observation. |
| 128 Oz Filling Throughput | 60 BPM | Observation Recorded SKU filling rate | Applies to: Line 1 Filler Valve and Product Return Upgrade Portfolio-reported SKU filling rate in the Line 1 filler case; no before/after rate comparison is supplied for this observation. |
| 750 ML Filling Throughput | 125 BPM | Observation Recorded SKU filling rate | Applies to: Line 1 Filler Valve and Product Return Upgrade Portfolio-reported SKU filling rate in the Line 1 filler case; no before/after rate comparison is supplied for this observation. |
Protected food safety, reduced leaking and spraying, reduced foaming, improved cleanability, supported the dry-floor initiative, and improved filler reliability.
Coordinated 44 self-sealing filler valves; custom slide ring assembly; upper and lower manifolds; cam ring/ramp; guide rods; rollers; return tank; return pump; level probes; sensor; pump-down relay; contactors; MCPBs; PLC-to-starter wiring; sanitary pump; vendor startup and training.
Reduced filler contamination and product-handling risk, measured by 44 Filler-valve supplier self-sealing valves, >=85 GPM feed capability, AFE #23-330366, and $229,652.23 capital scope, by replacing legacy filler valves and separating fill supply from product return.
44 filler valves; >=85 GPM feed capability; AFE; 64 oz at 120 BPM; 128 oz at 60 BPM; 750 mL at 125 BPM; smaller SKU improvement.
Food and Beverage Manufacturer
Owned the full project lifecycle, from capital planning through commissioning and post-startup support. The filler and conveyor had to operate as one packaging system.
TSK-000138 · Technical context
Line 1 Filler and Conveyor Upgrade
Recorded applicationTSK-000829 · Action
Line 1 Filler and Conveyor Upgrade
TSK-000830 · Action
Line 1 Filler and Conveyor Upgrade
TSK-000831 · Action
Line 1 Filler and Conveyor Upgrade
Application context. What evidence supports the approval and subsequent control of scope?
Action
Applies capabilities
ACTIVITIES IN CONTEXT
TSK-000109 · Action
Line 1 Filler Valve and Product Return Upgrade
TSK-000110 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000111 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000112 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000113 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000114 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000115 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000116 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000117 · Technical scope
Line 1 Filler Valve and Product Return Upgrade
TSK-000118 · Action
Line 1 Filler Valve and Product Return Upgrade
TSK-000119 · Method
Line 1 Filler Valve and Product Return Upgrade
TSK-001061 · Action
Line 1 Filler Valve and Product Return Upgrade
TSK-001062 · Action
Line 1 Filler Valve and Product Return Upgrade
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.
Supplier Participation
Vendor Contribution
Equipment-vendor startup and training were part of the filler-retrofit delivery scope.
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.
Led the 44-valve hygienic retrofit and coordinated return capacity with conveyor behavior and product supply. Used SKU-level operating evidence to compare performance, keeping the improvement tied to the actual package mix. The engineering connected line capacity with sanitation, maintainability and production continuity.
