PRJ-A-010 · Food and beverage manufacturer

Ceramic Crossflow Filter System + Ion Exchange Trial

Owned the full lifecycle of this project, connecting capital planning, engineering, delivery and operating readiness. Filtration performance depended on the entire cleaning and product-flow cycle. Filter selection, sanitary routing, automatic valves and cleaning effectiveness determined both usable capacity and the operating burden on the plant.

Conceptual engineering visualization: Ceramic Crossflow Filter System + Ion Exchange Trial
Conceptual engineering visualization · AI generated

The Operating Context

Operating Context

Filtration performance depended on the entire cleaning and product-flow cycle. Filter selection, sanitary routing, automatic valves and cleaning effectiveness determined both usable capacity and the operating burden on the plant.

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.

Purpose & Engineering Scope

Purpose and Scope

Business Purpose

Reduced operating expense by $229K per year by eliminating consumables and extending CIP intervals.

Technical Scope

CIP and Process Clarification

The Work & Its Outcomes

Work and Outcomes

Engineering Approach

  • Compared filter options using demand, capacity, operating cost and lifecycle considerations.
  • Integrated CIP, automatic valves, hygienic flow paths, instrumentation and dedicated electrical feeds.
  • Developed operating and preventive-maintenance follow-up, modular expansion and clean-water-flux tracking.

Results, Targets & Design Context

  • Recorded approximately $229k/year in operating-expense reduction.
  • CIP interface engineering recorded more than 50% longer run time between cleaning cycles. Approximately 90% flux recovery and less than 0.4 NTU turbidity describe the separate 2018 laboratory baseline.
  • The cost study identified $65k/year in labor reduction and an estimated 5,850 lb/year less landfill waste; these are components of the same system, not additional portfolio-wide totals.
  • A 50% modular expansion route and future capital deferral were planning alternatives.

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

AFE Development, Procurement and Bid Evaluation

Connected Activities

Project Controls and Governance

Connected Activities

Delivery Improvement and Quantitative Controls

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

Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000038 · Method

Built Cost-per-Gallon, NPV, Breakeven, Labor, Media, Electrical, CIP, Membrane-Life, and Expansion-Deferral Models.

Ceramic Filtration Cost-per-Gallon and NPV Model

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000039 · Method

Clarified Current Process, Option 1 / Option 2 Design Basis, Prefilter Cost, Membrane Replacement Model, and CIP / Product-Segregation Strategy.

Ceramic Crossflow Option Comparison and AFE Clarification

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000042 · Method

Used Ceramic Membranes, Automated CIP, Carbon-Path Reuse, Stack-Filter Bypass, and Product-Path Segregation

Ceramic Filtration Sustainability and Operator Exposure Reduction

Recorded application

Statistical Quality and Process Analytics

Connected Activities

Optimization and Operations Research

Supply Chain and Inventory Analysis

Connected Activities

Uncertainty, Reliability and Queueing

Connected Activities

Experimental Design and Model Validation

Connected Activities

Production-Rate Driver Analysis

Connected Activities

Work Measurement and Methods Engineering

Quality Engineering and Structured Improvement

Connected Activities

Engineering Option Studies and Operating Models

Connected Activities

Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000038 · Method

Built Cost-per-Gallon, NPV, Breakeven, Labor, Media, Electrical, CIP, Membrane-Life, and Expansion-Deferral Models.

Ceramic Filtration Cost-per-Gallon and NPV Model

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000039 · Method

Clarified Current Process, Option 1 / Option 2 Design Basis, Prefilter Cost, Membrane Replacement Model, and CIP / Product-Segregation Strategy.

Ceramic Crossflow Option Comparison and AFE Clarification

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000042 · Method

Used Ceramic Membranes, Automated CIP, Carbon-Path Reuse, Stack-Filter Bypass, and Product-Path Segregation

Ceramic Filtration Sustainability and Operator Exposure Reduction

Recorded application

KPI Ownership and Performance Interpretation

Connected Activities

Analytical Capability and Practical Application

Connected Activities

Related methods and applications

Technical Systems Ownership

Process Filtration and Clarification

Connected Activities

Conceptual engineering illustration: control panel fabrication

TSK-000035 · Method

Coordinated Installation and Integration of the Ceramic Membrane Ceramic-Crossflow System, Automated Manifolds, CIP, Carbon Paths, Stack Filters, Tank-Level Automation and Utilities/Controls

Ceramic Membrane Ceramic-Crossflow System Integration

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000038 · Method

Built Cost-per-Gallon, NPV, Breakeven, Labor, Media, Electrical, CIP, Membrane-Life, and Expansion-Deferral Models.

Ceramic Filtration Cost-per-Gallon and NPV Model

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000039 · Method

Clarified Current Process, Option 1 / Option 2 Design Basis, Prefilter Cost, Membrane Replacement Model, and CIP / Product-Segregation Strategy.

Ceramic Crossflow Option Comparison and AFE Clarification

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000040 · Method

Specified a Batch-Specific 250 Micrometer Prefilter Sock for the Carbon-Treated-Vinegar Path to Capture CA1 Activated-Carbon Particles Before Ceramic Filtration

Carbon-Treated Vinegar Prefilter and Fouling Prevention

Application context. Are cleaning states, chemistry, flow and release logic mutually consistent?

Conceptual engineering illustration: ceramic filtration

TSK-000042 · Method

Used Ceramic Membranes, Automated CIP, Carbon-Path Reuse, Stack-Filter Bypass, and Product-Path Segregation

Ceramic Filtration Sustainability and Operator Exposure Reduction

Recorded application
Conceptual engineering illustration: process formulation

TSK-001013 · Study design

Developed a Feasibility Plan for Adsorption Kinetics, Isotherms, Packed-Column Trials, Regeneration and Scale-Up Inputs, and Screened Manufacturers for Food Compatibility, Lifecycle, Disposal and Pilot Support

Ceramic Crossflow Filter System + Ion Exchange Trial

Application context. Which formulation factors change functionality and manufacturing compatibility?

Industrial Automation, Controls and OT Networks

Connected Activities

Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000046 · Action

Ceramic-Filter Electrical Feeds, Controls and CIP Integration

Ceramic Filter Electrical and Controls Coordination

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000047 · Method

Used Dedicated Electrical Feeds, OT Ethernet Connectivity, Tank-Level Wiring, Solenoid Valve Control, Leak Isolation, and Automated CIP Logic

Ceramic Filter Electrical and Controls Coordination

Recorded application

Wastewater, Recovery and Environmental Systems

Connected Activities

Conceptual engineering illustration: maintenance reliability

TSK-000063 · Method

Preventive-Maintenance and CIP Follow-Up Requirements

Ceramic-Filter SOP, Preventive-Maintenance and CIP Audit

Recorded application

Bulk Transfer and Batch Control

Instrumentation and Tank Measurement

Connected Activities

Conceptual engineering illustration: control panel fabrication

TSK-000035 · Method

Coordinated Installation and Integration of the Ceramic Membrane Ceramic-Crossflow System, Automated Manifolds, CIP, Carbon Paths, Stack Filters, Tank-Level Automation and Utilities/Controls

Ceramic Membrane Ceramic-Crossflow System Integration

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000046 · Action

Ceramic-Filter Electrical Feeds, Controls and CIP Integration

Ceramic Filter Electrical and Controls Coordination

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000047 · Method

Used Dedicated Electrical Feeds, OT Ethernet Connectivity, Tank-Level Wiring, Solenoid Valve Control, Leak Isolation, and Automated CIP Logic

Ceramic Filter Electrical and Controls Coordination

Recorded application

Electrical Power and Hazardous-Area Interfaces

Connected Activities

Conceptual engineering illustration: control panel fabrication

TSK-000035 · Method

Coordinated Installation and Integration of the Ceramic Membrane Ceramic-Crossflow System, Automated Manifolds, CIP, Carbon Paths, Stack Filters, Tank-Level Automation and Utilities/Controls

Ceramic Membrane Ceramic-Crossflow System Integration

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000046 · Action

Ceramic-Filter Electrical Feeds, Controls and CIP Integration

Ceramic Filter Electrical and Controls Coordination

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000047 · Method

Used Dedicated Electrical Feeds, OT Ethernet Connectivity, Tank-Level Wiring, Solenoid Valve Control, Leak Isolation, and Automated CIP Logic

Ceramic Filter Electrical and Controls Coordination

Recorded application

Building Envelope, Ventilation and Site Protection

Chemical Storage, Dosing and Treatment

Acetation, Fermentation and Process Support

Connected Activities

Conceptual engineering illustration: control panel fabrication

TSK-000035 · Method

Coordinated Installation and Integration of the Ceramic Membrane Ceramic-Crossflow System, Automated Manifolds, CIP, Carbon Paths, Stack Filters, Tank-Level Automation and Utilities/Controls

Ceramic Membrane Ceramic-Crossflow System Integration

Recorded application
Conceptual engineering illustration: project controls

TSK-000037 · Method

Coordinated Automated CIP Sequencing, NaOH /NaOCl Cleaning, Bypass/Recirculation Loops, HMI Controls, Membrane Testing, and Clean-Water Flux Validation

Ceramic Filter CIP Interface Engineering

Application context. Can product-contact paths be cleaned, segregated and operated within their hygienic scope?

Conceptual engineering illustration: ceramic filtration

TSK-000039 · Method

Clarified Current Process, Option 1 / Option 2 Design Basis, Prefilter Cost, Membrane Replacement Model, and CIP / Product-Segregation Strategy.

Ceramic Crossflow Option Comparison and AFE Clarification

Recorded application
Conceptual engineering illustration: control panel fabrication

TSK-000041 · Method

Coordinated Automated Infeed / Permeate Manifolds, Separate Product Paths, CIP Valve Automation, and Air-Push Clearing

Automated Infeed / Permeate Manifold and Vinegar Path Segregation

Recorded application
Conceptual engineering illustration: ceramic filtration

TSK-000042 · Method

Used Ceramic Membranes, Automated CIP, Carbon-Path Reuse, Stack-Filter Bypass, and Product-Path Segregation

Ceramic Filtration Sustainability and Operator Exposure Reduction

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000046 · Action

Ceramic-Filter Electrical Feeds, Controls and CIP Integration

Ceramic Filter Electrical and Controls Coordination

Recorded application
Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000047 · Method

Used Dedicated Electrical Feeds, OT Ethernet Connectivity, Tank-Level Wiring, Solenoid Valve Control, Leak Isolation, and Automated CIP Logic

Ceramic Filter Electrical and Controls Coordination

Recorded application
Conceptual engineering illustration: maintenance reliability

TSK-000063 · Method

Preventive-Maintenance and CIP Follow-Up Requirements

Ceramic-Filter SOP, Preventive-Maintenance and CIP Audit

Recorded application
Technical scope and recorded applications

Process Filtration and Clarification

Separation work connected centrifuges, ceramic filtration, ion-exchange testing, sanitary flow paths and CIP. Evaluated capacity, product quality, cleaning, consumables and recovery, then coordinated utilities, controls, supplier interfaces and operator requirements. The system perspective linked separation performance with downstream production and wastewater effects.

Applied Activities

Conceptual engineering illustration: control panel fabrication
Conceptual engineering illustration: ceramic filtration
Conceptual engineering illustration: ceramic filtration
Additional technical detail
Explore 10 detail records
  • Competency and project record

    Coordinated pumps, valves, instruments, automated CIP, product routing, controls, acceptance testing, and operator handoff for ceramic crossflow filtration; About $229,000/year OPEX reduction; estimated 5,850 lb/year solid-waste reduction

  • Competency and project record · R&D supplement

    Coordinated ion-exchange decolorization evaluation within the vinegar-polishing workstream, including bench-method review and a proposed supplier pilot before any production decision.

  • Sanitary and aseptic: Project mapping

    PRJ-A-010 | Ceramic Crossflow Filter System and Ion Exchange Trial | classification ASEPTIC_OR_HYGIENIC_PRODUCT_PROCESSING

  • Sanitary and aseptic: Controlled case details

    Coordinated ion-exchange evaluation for decolorization within the broader vinegar-polishing workstream.

  • Sanitary and aseptic: Controlled case details

    Successful trial coordination recorded.

  • Benefit validation plan

    Compare annualized consumables, CIP frequency, waste quantities and filtrate quality with the earlier filtration process.

  • Primary project risk

    Delivery / Execution.

  • Project governance scope

    Capital authorization, supplier and stakeholder coordination, QA/QC, commissioning planning and technical turnover documentation.

  • Engineering dependency

    Ceramic polishing and loadout. Downstream polishing supports the WDV/wine-vinegar production and truck-loading sequence.

Project Activities

Conceptual engineering illustration: control panel fabrication

TSK-000035 · Method

Coordinated Installation and Integration of the Ceramic Membrane Ceramic-Crossflow System, Automated Manifolds, CIP, Carbon Paths, Stack Filters, Tank-Level Automation and Utilities/Controls

Ceramic Membrane Ceramic-Crossflow System Integration

Conceptual engineering illustration: project controls

TSK-000037 · Method

Coordinated Automated CIP Sequencing, NaOH /NaOCl Cleaning, Bypass/Recirculation Loops, HMI Controls, Membrane Testing, and Clean-Water Flux Validation

Ceramic Filter CIP Interface Engineering

Conceptual engineering illustration: ceramic filtration

TSK-000039 · Method

Clarified Current Process, Option 1 / Option 2 Design Basis, Prefilter Cost, Membrane Replacement Model, and CIP / Product-Segregation Strategy.

Ceramic Crossflow Option Comparison and AFE Clarification

Conceptual engineering illustration: control panel fabrication

TSK-000041 · Method

Coordinated Automated Infeed / Permeate Manifolds, Separate Product Paths, CIP Valve Automation, and Air-Push Clearing

Automated Infeed / Permeate Manifold and Vinegar Path Segregation

Conceptual engineering illustration: ceramic filtration

TSK-000042 · Method

Used Ceramic Membranes, Automated CIP, Carbon-Path Reuse, Stack-Filter Bypass, and Product-Path Segregation

Ceramic Filtration Sustainability and Operator Exposure Reduction

Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000046 · Action

Ceramic-Filter Electrical Feeds, Controls and CIP Integration

Ceramic Filter Electrical and Controls Coordination

Conceptual engineering illustration: electrical infrastructure retrofit

TSK-000047 · Method

Used Dedicated Electrical Feeds, OT Ethernet Connectivity, Tank-Level Wiring, Solenoid Valve Control, Leak Isolation, and Automated CIP Logic

Ceramic Filter Electrical and Controls Coordination

Conceptual engineering illustration: maintenance reliability

TSK-000063 · Method

Preventive-Maintenance and CIP Follow-Up Requirements

Ceramic-Filter SOP, Preventive-Maintenance and CIP Audit

Project Measures

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 or outcomeValue or resultMeaning and operating scope
Operating Measureapproximately 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.

Turbidity0.26 to 0.39 NTUBaseline
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.

Ceramic-crossflow operating-expense reductionApproximately $229,000/year per documented implementationEleven documented implementations: $2,519,000/year combined. The related $65,286/year labor reduction is excluded from the combined total to avoid overlap.
Recorded outcomeRecorded approximately $229k/year in operating-expense reduction.Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded outcomeCIP interface engineering recorded more than 50% longer run time between cleaning cycles. Approximately 90% flux recovery and less than 0.4 NTU turbidity describe the separate 2018 laboratory baseline.Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded outcomeThe cost study identified $65k/year in labor reduction and an estimated 5,850 lb/year less landfill waste; these are components of the same system, not additional portfolio-wide totals.Ceramic Crossflow Filter System + Ion Exchange Trial
Recorded outcomeA 50% modular expansion route and future capital deferral were planning alternatives.Ceramic Crossflow Filter System + Ion Exchange Trial

Explore the Case Studies

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Workstream & Initiative

Manufacturing Facility Implementations

Related facility implementations are part of this project. Their operating conditions, equipment and interfaces are considered within the same project lifecycle.

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