Treehouse Foods, Inc.

Optimizing Peanut Butter Production with a Scrap Surface Heat Exchanger System

RPA Engineering provided comprehensive engineering and design services for the installation of a scrap surface heat exchanger system optimized for continuous processing of viscous materials, specifically peanut butter production. The project for two production lines required a multi-disciplinary engineering approach, covering structural, mechanical, electrical, and controls engineering to ensure efficient and reliable system integration within the existing food and beverage manufacturing facility.

Challenge

The client needed to upgrade its production capabilities with a new heat exchanger system while working within the constraints of existing infrastructure. The viscous nature of peanut butter processing demands specialized considerations for material handling, heat transfer efficiency, and system controls.

Initial Assessment

The engineering team conducted a thorough investigation of existing conditions:

• Structural analysis of slab foundations and roof supports to ensure adequate load-bearing capacity
• Comprehensive survey of current piping layouts and routing options
• Documentation of electrical panel capacity and distribution
• Evaluation of existing control systems and integration requirements

Engineering Solutions

Structural Engineering:

• Design of roof structure reinforcement and bracing to accommodate the weight of the heat exchanger and associated equipment.
• Design of a foundation or base for the heat exchanger.
• Design of support structures for piping systems.

Mechanical Engineering:

• Refinement of the overall equipment layout, considering existing unit loads, elevations, clearances, and generating detailed diagrams.
• Sizing and design of piping systems for the peanut butter and heating/cooling media.
• Development of utility flow diagrams.
• Sizing and routing of pumps to handle the viscous peanut butter.

Electrical Engineering:

• Design and coordination of electrical connections for all new equipment, ensuring compatibility with the existing electrical system.

Controls Engineering:

• Development of programming logic for the heat exchanger control system, including temperature control, flow rate management, and safety interlocks.
• Creation of acceptance tests to validate system performance.
• Development of Variable Frequency Drive (VFD) parameters for optimal pump control.
• Implementation of Quality Assurance/Quality Control (QA/QC) procedures for design and programming.

Outcome and Impact

RPA Engineering delivered a comprehensive solution addressing project challenges while demonstrating RPA Engineering’s expertise in providing trusted engineering solutions for complex processing systems in food and beverage processing facilities. By addressing the unique challenges associated with viscous material handling and integrating the new system seamlessly into the existing facility, RPA Engineering delivered a successful project that optimized peanut butter production and improved product quality – demonstrating effective integration of structural, mechanical, electrical, and controls engineering to create a robust solution for specialized food processing applications.