Converted a manually operated process that reclaimed board material from the planer mill to a manually operated sorting station, which was then manually loaded to trucks via forklift buckets for transport to the end-user. This process was modified by adding a series of conveyors which automatically transfer this product from the planer mill to a newly constructed loadout building that can accommodate (2) two 53’ trailers. Once the product is received at the loadout building, the trailers are loaded automatically via automation to fill each trailer one at a time, front to back.

Design and Installation of new 120bpm packaging line for cleaning products. System includes new filler, capper, sleever, case packer, and conveying system. The system feeds into a repurposed palletizer. Designed and installed a new product delivery system from the process to the filler. Project included new switch gear for power feed to power distribution panel, new 9 section MCC, new ControlLogix control panel (fabricated at TA panel shop) and Factory Talk operator stations.

Performed building modifications (walls, doors, foundations, drains, etc.) to install new batching system to include batching tanks, product storage tanks, and new CIP System. Liquid and powder raw materials through batching and valve matrix to finished product tanks. Additional valve matrix installed to feed finished product to packaging lines. New CIP cleans two paths simultaneously. New control system to include ControlLogix PLC’s, remote panels and HMI stations running Aveva Wonderware. New power distribution with additional motor control centers. 3d design effort for more efficient constructability.

Technical Associates provided full engineering and start-up support associated with the installation of a ceramic filtration system that separates waste yeast from the fermentation process and clear beer. Prior to installation of this system, this waste yeast/beer mixture was sent to process sewer impacting the brewery with significant sewer costs. With the new Ceramic Filtration System in operation, the brewery is able to sell concentrated yeast slurry for use in animal feed products, and recover clear beer to blend with existing beer during secondary fermentation. The ROI from the reduced sewer costs coupled with a marketable waste product and recovered beer was substantial. TA provided engineering support from project conception through final start-up in the areas of Mechanical/Process, Electrical/I&C, Structural and Programming. TA was an integral part of the Client Project Design team working with the major equipment suppliers (Filtration System, Pumps and Heat Exchangers) and the Breweries Corporate Team since this was the first full-scale installation in a US Brewery.

In addition to the engineering associated with installation of the Ceramic Filtration System, TA was involved in the design of the following support systems for this project:

• Dedicated CIP System
• Large Mix-Proof Valve Matrix
• Converting Tanks for Storage Waste Yeast and Recovered Beer Including Tank CIP Modifications
• Waste Yeast Load-Out System (Tank, Pump and Truck Load Out Stations)
• Process Drains

TA has supported the brewing industry for over 12 years in the areas of sanitary/process design, water treatment, utilities (including Ammonia) and packaging.

TA’s Mission

To design, model, integrate, and construction manage the install of a filtration system intended to save this customer significant dollars on process waste while supplying additional value by returning good product into the process.

A large General Contractor that had made a name for themselves in the building industry was invited to perform a turnkey proposal for a major nutrient and food additive company. The general contractor needed to supplement their expertise in construction with process and automation engineering expertise. After reaching out to their numerous clients for references on a solid engineering and automation provider they invited Technical Associates to partner with them on this and several future endeavors to provide clients with a turnkey engineered process solution in new construction.

Our first venture was this new processing facility and expanded office space to triple an existing site’s capability. Technical Associates specified and solicited bids on all equipment and technologies and then designed and integrated the equipment into a flexible process that exceeded the client’s requirements while finding ways to save the client money in equipment, installation and operating costs. Technical Associates was the focal point (overall program manager) for the GC’s sub-contractors, the equipment vendors and the client. After achieving the start-up on-time and reaching designed rates well sooner than the client expected, Technical Associates solidified its position with this design, build firm and the client.

Technologies specified, designed and integrated included, pneumatic conveying, odor treatment, hydraulic power systems, oil heating systems and jacketed equipment, compressed air, cooling towers, dust control, explosion suppression and containment systems, static control and grounding, potable, process and fire water systems, housekeeping vacuum systems, electrical distribution, power and control systems and instrumentation. TA proved its design capabilities and is now involved in the second such facility with others planned in the near future.

TA’s Mission

Develop an evolving bench top concept into a manufacturing facility to meet a global product launch scheduled in the same calendar year. Work with the development group to identify all of the possible process solutions for each of 4 products to be simultaneously produced and designed flexibility into and out of the “heart” of the process area to achieve the project’s initial goals while allowing for the seamless integration of the project’s future goals.

Technical Associates was invited to participate in the expansion of a strategically important beverage manufacturing plant which essentially doubled the size of this facility to accommodate the a major and innovative initiative for this customer – a landmark rollout for the client and a first ever project and end product of its kind. TA was selected to self-perform the process expansion to support this initiative; a result of almost 20 years executing successful process and automation engineering projects for this plant and its corporate owner.

Technical Associates was part of a coalition of vendor partners all working together to deliver against logistically and technically challenging obstacles resulting from running a legacy plant while expanding utilities and infrastructure to support a greatly expanded (new) facility. TA’s in depth knowledge of the facility itself, our awareness and strict adherence to this customer’s exacting standards and expectations, and our proven process and automation skills were brought to bear to deliver the process expansion on schedule and within budget.

This particular project opportunity allowed TA to also demonstrate its evolution into a full service turnkey provider as TA manufactured over 45 process skids for this installation as well as self-performing the installation of the process system. From concept to design, from fabrication to install, from automation to start-up, TA successfully delivered a one stop solution for one of the most critical elements of the overall initiative – the process itself. TA’s ability to deliver the project in this fashion allowed the customer to focus on the larger picture and the overall integration of many aspects of this expansion without the worry of the coordination and possible conflicts or misses of multiple vendors involved in a vital and complex process expansion.

TA’s Mission

To deliver a one stop solution from concept through start-up on time and within budget while assisting the customer with coordination efforts to ensure all vendor partners would integrate well to successfully deliver a “game changing” project for the client.