APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-059 · Engineering case
Diagnosed and scoped a Line 2 pasteurizer rebuild to restore thermal control, divert logic, safety interlocks, and regulatory readiness.
The system failure involved control logic, valve condition, dwell time, temperature recording, divert logic, manual-switch behavior, and hot-water set performance, not a simple heat-exchanger issue.
Diagnosed failed pasteurizer logic/hardware; missing or inoperative divert, steam, and flow control valves; loss of loop temperature control; overheating/seal-damage risk; underprocessed-product risk; manual-switch hazards; scoped FDV01 divert valve, FCV01/02 temperature valves, flowmeter, RTDs, VFD-controlled pumps, chart recorder validation, high-temp cutout, auto shutdown, PLC/HMI coordination, hot-water set redesign, kosher CIP compatibility, 210 F / 3-hour CIP hold, product recovery/air-blow future path, filler return strategy, and chart recorder calibration/restoration.
Defined the pasteurizer rebuild, safety interlocks, thermal-control changes and compliance-readiness requirements.
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 |
|---|---|---|---|
| Existing Hold-Tube Length | 80 ft | Baseline Existing configuration | Applies to: Line 2 Pasteurizer and Hot Water Set Rebuild 80 ft existing hold tube |
| Pasteurizer Design Flow | 115 GPM | Design Parameter Design demand | Applies to: Line 2 Pasteurizer and Hot Water Set Rebuild 115 GPM design rate |
| Required Hold-Tube Length | 171 ft | Design Parameter Calculated design requirement | Applies to: Line 2 Pasteurizer and Hot Water Set Rebuild 115 GPM design — 171 ft required length |
| Existing Hold-Tube Sufficiency Flow | 54 GPM | Scenario or Model Result Calculated capacity limit | Applies to: Line 2 Pasteurizer and Hot Water Set Rebuild Existing 80 ft hold tube — 54 GPM sufficiency basis |
Defined rebuild controls intended to address food-safety, overheating, seal-damage, and underprocessed-product risks and improve kosher CIP and startup control.
Diagnosed failed pasteurizer logic/hardware; missing or inoperative divert, steam, and flow control valves; loss of loop temperature control; overheating/seal-damage risk; underprocessed-product risk; manual-switch hazards; scoped FDV01 divert valve, FCV01/02 temperature valves, flowmeter, RTDs, VFD-controlled pumps, chart recorder validation, high-temp cutout, auto shutdown, PLC/HMI coordination, hot-water set redesign, kosher CIP compatibility, 210 F / 3hrCIP hold, product recovery/air-blow future path, filler return strategy, and chart recorder calibration/restoration.
Missing or inoperative divert valve.
Missing or inoperative steam valves.
Missing or inoperative flow-control valves.
Overheating and seal-damage risk.
Risk of underprocessed product.
Hazards from manual switching.
Improvedpasteurizerrebuild readiness, measured by identifying an 80 ft hold tube limitation against 115 GPM design demand and confirming a 171 ft required length, by auditing thermal control, divert valves, hold-time compliance, instrumentation, and HMI/PLC safety logic.
80 ft existing hold tube; 115 GPM design rate; 171 ft required length; 54 GPM sufficiency basis; exit temperatures varied from 50 F to 250 F under manual-switch behavior; hold-tube-in chart pen functional.
Food and Beverage Manufacturer
Owned the full project lifecycle, from capital planning through commissioning and post-startup support. Pasteurization depends on the relationship between flow, holding time and temperature.
TSK-000141 · Technical context
Line 2 Pasteurizer Upgrades
TSK-000832 · Action
Line 2 Pasteurizer Upgrades
TSK-000833 · Action
Line 2 Pasteurizer Upgrades
TSK-000834 · Action
Line 2 Pasteurizer Upgrades
Action
Applies capabilities
ACTIVITIES IN CONTEXT
TSK-000120 · Action
Line 2 Pasteurizer and Hot Water Set Rebuild
TSK-000126 · Action
Line 2 Pasteurizer and Hot Water Set Rebuild
TSK-000127 · Method
Line 2 Pasteurizer and Hot Water Set Rebuild
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.
Missing or inoperative divert, steam, and flow control valves
Loss of loop temperature control
Overheating/seal-damage risk
Underprocessed-product risk
Manual-switch hazards
Loss of loop-temperature control.
Slide 1: Divert to fill tank; FDV01 described as inoperable and forced open.
Slide 2: Control Panel Cleanup; Controls Prior to Cleanup; Post Cleanup Return to OEM. This is the deck's only explicit completed-state claim.
Slide 3: Missing Controls ?; High Temp Cutout; Hot Water Set I/P Shut off; Product Temp I/P (3-9 & 9-15) PSI; Hot Water Set I/P 3-9 PSI.
Slide 4: PRV leaking and does not hold pressure; two modulating valves are 2 inches and the slide says they should be 1 inch and 3/4 inch; both fail to hold seal and require rebuild; one has significant mechanical failure; both use the same Hot Water Set I/P 9-15 PSI control solenoid.
Slide 5: product-temperature valve FCV02 broken, 3-9 PSI; FCV01 missing, 9-15 PSI.
Slide 6: Hold Tube In stated as the only working recorder pen and the value recorded for quality control; suitability is questioned; hot-water setpoint stated as 250 F; recorder photograph shows 115, 159, 161, and 159; lower controllers show 1163/1000 and 1597/1600 without legible decimal placement; visible labels identify Channel 1 red pen product out, Channel 3 blue pen hold tube in, and Channel 4 apparently black pen hold tube out; Channel 2 begins green pen hot water but its final document files is blurred.
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.
Reviewed hold-tube length, process flow and thermal-control requirements, translated those requirements into the upgrade scope, and coordinated production, quality and utility interfaces. The delivery approach connected the design basis with controls verification and operating readiness.
