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Name-Brand Food Manufacturing Company Achieves Flexibility, Accuracy and Cost Efficiency

Case Study /

Name-Brand Food Manufacturing Company Achieves Flexibility, Accuracy and Cost Efficiency

Objective: Expand operations through the addition of a new line, upgrade mechanical equipment if needed, understand total project cost.

Project Scope: This assignment was with a leading provider of specialized ingredients to the food manufacturing industry, and with multiple “house branded” products, dedicated to high quality and quick delivery. Installation of a new manufacturing line, and commitments to sustainability initiatives caused the need to evaluate existing mechanical and electrical infrastructure.  Stark Tech Group was engaged to assess key areas of infrastructure, update facility drawings based on findings, and provide metering and a technology platform for manufacturing cost allocation.

Solution: Stark customized a solution that would achieve the customer’s objectives, including flexibility accuracy and cost effectiveness. Stark’s team acted as an extension of the customer’s team, ensuring facility needs met the long-term goals and objectives.

Stark’s strategy involved:

  • Review of each manufacturing process and delineate process loads to compare to building utility infrastructure system capacities.
  • Investigation of utility distribution systems to create diagrammatic drawings and scope the proper location for metering and data acquisition devices.
  • A plan to re-use databases, data acquisition devices, and building automation systems that were already paid for in order to procure information and provide visibility and across platforms. 
  • Install metering systems as needed to properly delineate the flow of utilities to key manufacturing processes for energy efficiency evaluation and energy cost allocation.
  • Process systems, including hot water, electricity, domestic water, and compressed air, were integrated.
  • Ongoing monitoring is in place to analyze the data and notify plant personnel when opportunities for energy savings exist.

Results: Stark was able to work with the customer to develop and implement a phased approach to address specific needs that cross multiple disciplines. Drawings were updated and are currently used in multiple ways from planning expansions to every day maintenance. Existing utility infrastructure was confirmed to be sufficiently sized for future needs, and several significant areas for addressing energy and product waste were identified and corrected.

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