Hummus Consolidation

Problem

With no additional footprint available, outdated on-site equipment, additional equipment from the now defunct hummus production location, and inefficient cleaning procedures, a full line analysis of all existing and prospective equipment was needed.

Sharpe Engineering played a critical role in addressing these challenges by providing front-end guidance and unbiased evaluation. The success of the project hinged on effectively managing several key factors. 

• Line Analysis and Coordination: Working with the client and equipment vendors, Sharpe determined what equipment would be required for proper line operation, which additions from the defunct plant would aid production, and areas where new equipment would prove vital.

• Design Complexity: Integrating the newly designed production line seamlessly with the facility’s existing infrastructure and equipment, while also managing shipping logistics and proper timeframe management.

• Operational Standards: Maintaining strict compliance with safety protocols and industry regulations throughout the design and installation process. 

Solution

A thoroughly designed and engineered line, blending existing equipment and processes from both facilities, with Sharpe providing upgraded components for optimal operation.

• 3D models covering tanks, piping, valves, and pigging system allowing for accurate line design and project planning.

CIP (Clean in Place) Skid Addition

• Drastically improving cleaning efficiency and reducing necessary down time.  

Cooling System

• New heat exchangers providing an increase in production volume.

Tanks, Line Controls and Instrumentation

• Modernized tanks, valves, and components, combined with automating previously manual processes, boosting throughput and increasing product integrity by setting consistent production parameters.

Installation and Integration

Results

Sharpe Engineering designed, integrated and installed a fully operational line in one location, successfully consolidating the production of two facilities into one existing footprint.

• Optimized Throughput: Production from two facilities was met and exceeded in one optimized footprint, doubling previous production without requiring any additional space.

• Significant Capital Savings: By successfully optimizing production, a costly building addition was not required, resulting in substantial client savings and the ability to invest in other business sectors.

• Higher Food Safety & Uptime: The combination of modernized sanitation procedures and line connectivity through controls and instrumentation created swift and safe line operation and cleaning.