Background

A major U.S.-based food company acquired a complete business with multiple product lines that was supported from a single, 150,000 sq. ft. European manufacturing location. Foth was hired to gather required information and develop the necessary documentation to remove, relocate and start up all production and support equipment. This equipment had to be split and relocated to two existing U.S.-based manufacturing locations in under a year.

Approach

We found that the existing processes maintained by operators and maintenance/engineering personnel were poorly documented. P&ID’s, balance and flow diagrams, assembly drawings, and power and controls drawings either didn’t exist or were limited in their capacity to document the existing equipment. Foth conducted short, intense data gathering sessions in Europe to acquire information. Appropriate documentation was then developed which allowed for a smooth facilitation of the relocation.

Results

Foth was able to develop a cost- and time-effective approach to managing foreign voltages and frequencies. The main product destination is now located in the U.S., which allowed for significant shipping cost savings. Foth was not only able to support our client’s relocation needs, but also a smooth installation and startup process within budget constraints.

Competency Used

  • Program & Project Management
  • Packaging
  • Process
  • Construction Management
  • Electrical & Controls
  • Raw material storage silos
  • Sugar grinding and conveying
  • Bulk liquids storage tanks
  • Flammable flavor handling
  • Dough mixing, portioning, rolling and punching
  • Addition of efficient through-bed drying
  • Finished product air conveying
  • High-speed packaging (weight & count fillers)
  • High-speed tray packing, tray over-wrapping and case packing
  • Robotic palletizing
  • Dust collection and explosion suppression