Foodline Projects case study Archives | Page 2 of 3

Case Study – Thermowell Replacement – CSL Biotechnology

Written on 8 December 2016.

CSL BIOTECHNOLOGY MANUFACTURING FACILITY, VICTORIA

PRIVIGEN THERMOWELL REPLACEMENT

CLIENT: CSL BIOTECHNOLOGY

YEAR: 2016

SECTOR: PHARMACEUTICAL

PROJECT SCOPE Foodline Projects was engaged to replace the thermowell transmitters in 10 different sectors of an operating plant. The project required specialised welders to operate in critical areas with clean and sanitised procedures and equipment to maintain the environments integrity. TECHNICAL EXPERTISE A team of four highly qualified tradesmen completed the project within the required timeline, using highly polished 316 stainless steel pharmaceutical grade tube. Orbital welding was used to weld 150 welds, replacing 90-95 thermowells in situ. During the orbital welding process, Foodline utilised ISO Din collets, a specialised collet for unique pipework sizes in use at the CSL plant. In the critical environment, specialised manual systems were used for weld preparation due to very limited access to some of the critical areas. QUALITY ASSURANCE Full traceability was mandatory for all fittings and weld maps, coupled with qualifications and drawing updates to CSL standards and QA requirements. Foodline complied with all pharmaceutical QA documentation and performed X-Ray NDT testing on completed welds. All sample welds were reviewed and daily weld tests performed to ensure commitment to quality workmanship in the CSL plant. FINAL OUTCOME Foodline provided highly skilled personnel to ensure the quality of installation was optimal for the client. CSL have commended Foodline on the quality of welds and workmanship.

Case Study – Water Farm & Boiler Upgrade – West End Brewery

Written on 29 June 2016.

WEST END BREWERY, SOUTH AUSTRALIA

WATER FARM & BOILER UPGRADE

CLIENT: LION

YEAR: 2013 – 2015

SECTOR: FOOD & BEVERAGE

PROJECT SCOPE WATER FARM The water farm relocation and installation was completed whilst the plant was at full running capacity. To ensure no loss of production, Foodline Projects implemented a phased installation of the new vessels whilst systematically decommissioning and phasing out the old water farm. This included 5 new water vessels and 4 Clean in Place (CIP) tanks. BOILER UPGRADE Two new boilers were installed using 350mm nominal bore steel pipework with the old boilers decommissioned and removed from the site. TEMPORARY WORKS Foodline Projects installed a large amount of temporary pipework to allow continuous production whilst vessels were changed out. These temporary works were then removed at the end of the project. SAFETY FIRST APPROACH The West End brewery upgrade ran for 2 years with 35 specialised welders from TFG Group onsite full time. To ensure the safety of their employees, sub-contractors and operations staff, Foodline Projects employed a dedicated onsite safety officer to oversee the project. As a result, 68,000 man hours were worked with zero safety incidents, MTIs or LTIs. This safety first approach was particularly pertinent given that the total shut down time for the installation was only 7 weeks.

Case Study – Bluetongue Consolidation Project – Warnervale & Abbotsford

Written on 29 June 2016.

BLUETONGUE CONSOLIDATION PROJECT, WARNERVALE & ABBOTSFORD

DISMANTLE & RELOCATION OF CIDER PLANT

CLIENT: CARLTON & UNITED BREWERIES

YEAR: 2014 – 2015

SECTOR: BREWING

WEALTH OF KNOWLEDGE Foodline Projects was engaged by Carlton & United Breweries to uninstall and then mechanically install the plant and equipment from Warnervale to the new cider making facility in Abbotsford. Foodline had comprehensive knowledge of both sites from previous installations and completed the project under budget and within time frame. SCOPE OF WORKS Foodline’s sequential removal was meticulously planned with careful handling of fermenters, bright beer tanks, sugar tanks, pumps and heat exchangers. The successful relocation to Abbotsford required the Foodline team to manage the projects transport, cranage, civil works and packaging to ensure precision installation of all equipment and tanks. Foodline was integral in the commissioning of all relocated equipment once in place at the new cider making plant. AUSTLINE FABRICATIONS TFG Groups Austline Fabrications division in Perth, Western Australia was awarded the design and fabrication of the access platforms, stairs and walkways. Fabricated in the purpose build factory in Welshpool they were then installed on site in Abbotsford to fit the new footprint of the cider making facility. TECHNICAL EXPERTISE Foodline successfully integrated the previous beer fermenters with extensive fabrication and modifications of the valve manifolds to be installed in the new plant as cider fermenters. TFG was chosen for this project due to our ability to sensitively remove utility plants including compressed air, boilers and cooling towers for resale.

foodline-projects-little-creatures-geelong

Case Study – Little Creatures Brewery, Geelong

Written on 2 March 2013.

LITTLE CREATURES BREWERY, GEELONG

BREWHOUSE

CLIENT: KRONES

YEAR: 2012 – 2013

SECTOR: BREWING

ICONIC BREWERY EXPANSION

The success of the Little Creatures Fremantle brand and subsequent buy out by brewing giant Lion led to a $60m investment in a new Little Creatures brewery located in Geelong, Victoria.

After the successful installation of the Fremantle brewhouse expansion, Foodline Projects was the obvious choice to install the new brewhouse, fermentation vessels and filtration tanks at the new site in regional Victoria.
The East Coast shift reduces transport costs across the Nullabor and allows for even greater expansion of the Little Creatures iconic brand.

MECHANICAL INSTALLATION

Foodline’s specialised team of fabricators, welders and fitters installed;

All process pipework
Filtration vessels
Fermentation tanks
Heat exchangers
Over 4,000 fittings and valves

Case Study – Harvey Fresh

Written on 20 February 2011.

HARVEY FRESH FILLING LINE

WESTERN AUSTRALIA

FILLING LINE

CLIENT: TETRA PAK

YEAR: 2011

SECTOR: DAIRY

FOOD PRODUCTION SPECIALISTS In 2011 Tetra Pak engaged Foodline projects to assist with the upgrade of a filling line at the Harvey Fresh flavoured milk production facility in Western Australia’s South West. Foodline Projects completed the installation using orbital welding techniques to ensure the highest quality finish and bacterial contamination. QUALITY ASSURANCE Due to the potential contamination in milk products, the highest level of aseptic, food grade orbital welding techniques were employed to guarantee the quality of the end product.

Case Study – Boags Brewery

Written on 20 February 2010.

BOAGS BREWERY TASMANIA

BREWHOUSE

CLIENT: KRONES & LION

YEAR: 2008 – 2010

SECTOR: BREWING

MAJOR PROJECT TEAM Foodline was originally engaged by Krones to install the new brewhouse, malt handling facilities and cellar upgrade at the brownfield site in Tasmania. Foodline’s success in this installation prompted brewery owners Lion to engage Foodline to complete the rest of the project which included a green beer centrifuge upgrade, fermentation system and filtration system upgrade. Foodline Projects showcased their project management capabilities by completing the four major installations on an existing brownfield site for two different clients without injury or unscheduled lost production time. BOAG’S EXPANSION The brewhouse was completed in 18 months and added capacity for another 50-million litres of beer product, which equates to around five-and-a-half million extra cases of Boag’s Premium, Boag’s Draft and Classic Blonde each year. PROJECT INNOVATION FERMENTATION The fermentation tanks were decommissioned and removed from the former Swan brewery site in Perth, refurbished by TFG’s Austline Fabrications in Perth and then transported to Tasmania for installation at the new Boags brewhouse. CELLAR UPGRADE The cellar upgrade posed an initial challenge as some of the walls were more than 2 meters thick requiring specialised machinery to drill holes for the new pipelines. FILTRATION SYSTEM Foodline Projects installed a candle filtration system at the brewery which included an upgrade to the yeast propagation system to guarantee the integrity of the yeast.