POWER provided multi-discipline engineering services for a new 170,000-square-foot greenfield french fry and preform potato processing facility. The project included design and installation support for complete french fry processing and packaging systems, plant electrical and process controls infrastructure, and the installation of a new, dual-bay substation. In addition to french fries, the plant also produced potato strips and patties.
- High-quality production on an accelerated schedule:After only eight weeks of operation, this facility was certified by McDonald’s to product “MAC” fries, considered the toughest product in the business to make due to rigid process specifications and extremely high quality requirements.
- Highly efficient and flexible packaging system:The case handling and palletizing system allows the main production line to palletize at either available palletizer, maximizing productivity. Upon completion, the entire packaging system outran the processing portion of the facility.
- Creative use of applications from other industries:An innovative adaptation of a trolley system used in meat processing was used to allow operator access to graders while also improving safety conditions and streamlining the grader sanitation process.
- Innovative infrastructure design:The project included a dual-bay substation utilizing arc-resistant metal-clad switchgear for secondary feeder distribution, 5 kV soft start motor control for ammonia refrigeration compressors, indoor 5 kV/600V secondary unit substations, and a 600 V motor control incorporating Device NET bus communication to a hybrid DCS plant control system.
- Industry-leading control system:This plant was the first potato processing plant to incorporate a DCS control system (Delta V) to integrate all instrumentation, controls, and electrical motor controls into a single system. At the time of construction, this plant boasted the highest levels of automation in the industry.
- Integration of new technology and tried-and-true standards for the potato processing industry
- Scale distribution system designed to supply product evenly to all scales and adjust distribution if a bagger or scale goes down.
- Innovative case-packing area layout designed to allow easy operator access to case packers and conveyor systems, facilitating efficient and responsive maintenance.
- Original bucket-wash system designed to efficiently sanitize scale pans and buckets while protecting integrity of expensive equipment.
- Complete Device NET network designed to connect all plant motor control centers (MCCs) – including individual MCC buckets and all electronic variable frequency drives – in the system, allowing remote, online monitoring of motors from the plant’s central control system.
- Central control system that monitors every motor, sensor, and instrument in the plant.
- 10 mVA substation, medium voltage electrical distribution, 480 mVA control system
- New systems for raw receiving unloading, potato blending, steam peeling, cutting system design, starch recovery system design, blanching, drying and fryer oil distribution.
- Process engineering and design for all major process equipment
- Material handling/packaging engineering and design services for all systems (freezer discharge and grading, through distribution and palletizing)
- Design, sizing, specification and layout for all process piping and process pumps
- Complete electrical engineering and design services for plant utility systems and instrumentation throughout the facility
- Equipment procurement and selection support services (bid package generation; coordination with vendors to define/improve equipment; support throughout the packaging equipment manufacturing and delivery process)
- Installation and start-up management and support