Weiner Process Upgrade

Faced with deteriorating cooking and chilling equipment for processing meat, a major food manufacturer elected to fabricate a new cooking and chilling tunnel while simultaneously refurbishing an old tunnel.  Concurrent upgrades to process controls, sanitation, metallurgy and operations enhancements were made within this schedule sensitive, strategic project.

Challenges:

• The re-skinned tunnel required metallurgy upgrades.
• The mechanical condition of the re-skinned tunnel was marginal due to being idle for a decade.
• Required a centralized CIP system capable of concurrent cleaning of two tunnels.
• Upgraded controls from Relay to PLC without risking installation schedule.
• Designed and installed state of the art sanitation upgrades to both tunnels. 

Benefits:

• Shop fabrication and modularization enabled short construction window to be met and no short shipments.
• CIP System design reduced sanitation downtime by 70%.
• PLC controls enhanced production capabilities.

Project Included:

• Re-skinning the smoke house and chill zones.
• Fabrication of all components on the new tunnel.
• CIP System design and installation.
• Control System replacement.
• Ejector redesign.
• Smoker burner flame safety system upgrades.
• New smoke, rinser and brine zone receptors.
• Upgraded steam cook coils and supply system.
• Upgraded condensate handling system.