APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIP

PRJ-A-003 · Food and beverage manufacturer

Line 1 Pasteurizer Repair

Owned the full lifecycle of this project, connecting capital planning, engineering, delivery and operating readiness. Unreliable steam shutoff can overheat product even when the rest of a pasteurizer is operating normally. The repair therefore centered on both tight isolation and controllable steam delivery.

Conceptual engineering visualization: Line 1 Pasteurizer Repair
Conceptual engineering visualization · AI generated

Workstream: Production and Packaging Modernization

The Operating Context

Operating Context

Unreliable steam shutoff can overheat product even when the rest of a pasteurizer is operating normally. The repair therefore centered on both tight isolation and controllable steam delivery.

Investigated valve alternatives, defined the repair boundary with operations and maintenance, and led the steam-control repair. Commissioning checks included steam shutdown behavior, connecting valve selection and control response to dependable pasteurizer operation.

Purpose & Engineering Scope

Purpose and Scope

Business Purpose

Restore dependable pasteurizer operation by re-establishing tight steam shutoff and controllable steam flow.

Technical Scope

Pasteurization and Thermal Process Control, Steam Valves and Piping, Instrumentation and Controls Coordination

The Work & Its Outcomes

Work and Outcomes

Engineering Approach

  • Investigated steam shutoff and control-valve alternatives.
  • Coordinated the repair boundary with plant operations and maintenance.
  • Led the steam-control repair that restored tight shutoff and controllable steam delivery.

Results, Targets & Design Context

  • Recovered dependable pasteurizer operation within the documented steam-control repair scope.
  • The option study identified a preferred repair approach; that estimate is separate from final project cost.

Project Delivery & Execution

Capital Planning and Full Lifecycle Ownership

Owned the full project lifecycle, from capital planning through engineering, procurement, construction, commissioning and operating readiness.
Full lifecycle ownership

  • Project Ownership

    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.

Connected Activities

Design and Multidisciplinary Coordination

Connected Activities

Recorded delivery responsibilities and activities

Owned capital planning and the full delivery lifecycle. The cards connect the applicable responsibilities with the recorded work.

Delivery Activities

Analytical Methods & Quantitative Decision Support

Financial and Capital Investment Analysis

Connected Activities

Statistical Quality and Process Analytics

Supply Chain and Inventory Analysis

Uncertainty, Reliability and Queueing

Production-Rate Driver Analysis

Quality Engineering and Structured Improvement

Engineering Option Studies and Operating Models

Connected Activities

KPI Ownership and Performance Interpretation

Analytical Capability and Practical Application

Technical Systems Ownership

Acetation, Fermentation and Process Support

Connected Activities

Technical scope and recorded applications

Steam and Boiler Systems

Connected boiler capacity, steam distribution, pressure reduction, condensate return and temperature control. Work included P&IDs, line and valve sizing, pressure-control analysis, steam-network repairs, instrumentation, insulation and commissioning. Treating heat delivery and condensate recovery as one system supported stable process conditions and maintainable operation.

Bottling, Packaging and Format Conversion

Coordinated fillers, cappers, pasteurizers, conveyors and packaging equipment with line layouts, utility connections and controls. Format changes included bottle and closure geometry, molds, change parts, sourcing and changeover readiness. Production flow, sanitation, safety and startup requirements shaped the complete line scope.

Additional technical detail
Explore 22 detail records
  • Competency and project record

    Steam shutoff, controllable steam flow, UDC/control and shutdown logic; Restored dependable pasteurizer operation

  • Sanitary and aseptic: Project mapping

    PRJ-A-003 | Line 1 Pasteurizer Repair | classification ASEPTIC_OR_HYGIENIC_PRODUCT_PROCESSING

  • Sanitary and aseptic: Problem scope

    The source attributes repeated overheating to steam-valve leak-by and failure to manually shut steam off overnight.

  • Sanitary and aseptic: Problem scope

    Reported consequences include pump failures, pressure spikes, and blown heat-exchanger seals.

  • Sanitary and aseptic: Problem scope

    The source states temperatures exceeded 300 degrees F.

  • Sanitary and aseptic: Problem scope

    It calls the work an emergency AFE and states that, at submission, work was scheduled through May 5 and no overheating had occurred during production hours.

  • Sanitary and aseptic: Problem scope

    Scope: Class IV TCV, two Class VI steam shutoff valves, condensate and steam piping modifications, UDC wiring and pneumatics, remote and onsite commissioning, and restoration of the heat-control loop.

  • Sanitary and aseptic: Equipment deliverables

    One-inch valve supplier JFC065S spring-return Class VI valve for hot-water-loop failover.

  • Sanitary and aseptic: Equipment deliverables

    Two-inch valve supplier JFC065S spring-return Class VI valve for overnight steam shutoff.

  • Sanitary and aseptic: Equipment deliverables

    Two-inch valve supplier DVC6200-D4 Class IV valve with DVC6200-HC digital positioner.

  • Sanitary and aseptic: Equipment deliverables

    A two-inch valve supplier control valve, exact source spelling, owned by Food and beverage manufacturer and sent to valve supplier for testing/remanufacture.

  • Sanitary and aseptic: Equipment deliverables

    Deliverables include installed and integrated control, safety, and shutoff valves; UDC logic; commissioned and verified heat loop; restored normal operation; and rework of prior modifications.

  • Sanitary and aseptic: Equipment deliverables

    Utilities/components: steam, condensate, hot-water pump and loop, and UDC wiring.

  • Sanitary and aseptic: Responsibilities and timeline

    James Warren: Project Lead, CapEx Engineer.

  • Sanitary and aseptic: Responsibilities and timeline

    Chris Buoy: Steam PE Support Engineer, Controls Specialist.

  • Sanitary and aseptic: Responsibilities and timeline

    Roger: commissioning specialist for boiler/combustion.

  • Sanitary and aseptic: Responsibilities and timeline

    Mechanical contractor: mechanical fabrication and installation.

  • Sanitary and aseptic: Responsibilities and timeline

    Controls integrator: system design and integration.

  • Sanitary and aseptic: Responsibilities and timeline

    Milestones stated: May 1 PO; May 2-3 hot-water materials; May 3-4 hot-water installation/wiring; May 4-5 hot-water commissioning/verification; May 16-17 steam materials; May 17-18 steam installation/wiring; May 18-19 steam commissioning/verification.

  • Benefit validation plan

    Review valve response, temperature behavior, startup/shutdown checks and maintenance callouts against the condition before repair.

  • Primary project risk

    Delivery / Execution.

  • Project governance scope

    Capital authorization, roadmap sequencing, construction coordination, QA/QC, commissioning planning and technical turnover documentation.

Project Activities

Project Measures

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 or outcomeValue or resultMeaning and operating scope
Reported Overheating Temperature> 300 deg FObservation
Reported abnormal condition

Applies to: Line 1 Pasteurizer Repair

Reported Overheating Temperature

Hot-Water Failover Valve Nominal Diameter1 inDesign Parameter
Specified equipment

Applies to: Line 1 Pasteurizer Repair

2025 heat-control repair — Hot-water failover valve nominal diameter

Overnight Steam Isolation Valve Nominal Diameter2 inDesign Parameter
Specified equipment

Applies to: Line 1 Pasteurizer Repair

2025 heat-control repair — Overnight steam isolation valve nominal diameter

Control Valve Nominal Diameter2 inDesign Parameter
Specified equipment

Applies to: Line 1 Pasteurizer Repair

2025 heat-control repair — Control valve nominal diameter

Existing Valve Remanufacture Nominal Diameter2 inDesign Parameter
Specified equipment

Applies to: Line 1 Pasteurizer Repair

2025 heat-control repair — Existing valve remanufacture nominal diameter

Recorded outcomeRecovered dependable pasteurizer operation within the documented steam-control repair scope.Line 1 Pasteurizer Repair
Recorded outcomeThe option study identified a preferred repair approach; that estimate is separate from final project cost.Line 1 Pasteurizer Repair

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Project delivery & execution ↗Technical systems ownership ↗Analytical methods & quantitative decision support ↗

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