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Morgan Consultants Saves Bakery Operation

Multi-Site Snack Expansion Project

Engineering and project management support for a high visibility, multi-site network optimization and expansion project of Kettle Chip production across the client’s North American manufacturing operations. The scope included product and equipment relocations and modifications of several production lines across various facilities. Unit Operations included frying, centrifuging, conveying, high-speed bagging and case packing, and all related infrastructure systems and building upgrades. Responsibilities included project scope documents, funding requests, detailed cost estimates, equipment procurement, scheduling for over twenty vendors, installation coordination, and equipment commissioning. Project complexity was elevated, as the primary Design/Build engineering firm had sub-contracted responsibilities to numerous other parties, requiring additional oversight by Morgan’s Project Manager to mitigate further delays.

HTC Oven Troubleshooting & Redesign

A major snack foods client faced challenges with a poor performing oven that adversely affected product quality, line reliability, and throughput. Morgan’s engineers provided start to finish SME support with leadership roles in a new oven selection process and installation. The collaborative team consisting of Morgan Consultants and client key stakeholders used a structured Failure Mode and Effects Analysis (FMEA) process to evaluate oven designs from three Best of Class manufacturers. Beyond the oven selection, Morgan Consultants managed the installation scope, contractor bidding and selection, and construction supervision. Lastly, the Morgan team provided SME support for a very successful commissioning and CQV process which included the entire production line with the newly integrated oven.

Beverage Process Safety Management Assessment

A major beverage client produces concentrated ingredients including colorings and flavorings that are then distributed to their other manufacturing sites for dilution into a variety of syrups for soft drinks, teas, juices, and other products. Due to the hazardous properties of the ingredients, each manufacturing site has to maintain a thorough and up to date Process Safety Management Program. Morgan was engaged to assess their existing documents and update as-builts. Extensive time was spent on-site editing the PFDs, collecting information on safety devices, validating electrical classifications, and surveying the condition of the processing equipment. After completion, all of the client’s documents met or exceeded OSHA requirements. Morgan’s work assisted the plant to be “audit ready” for internal and external audits.

Operational Assessment & Infrastructure Redesign

A small, privately-held company approached Morgan and requested assistance with developing a project for a new cracker line to increase their capacity. After the scope was approved, Morgan found used equipment that could be modified to fit the application, prepared detailed design that fit the line into the leased space, obtained building permits, arranged for the equipment installation, and provided operations specialists to commission and startup the line. The production capacity of the new line has exceeded client targets.

Raw material system upgrades

Provided Conceptual Design, Preliminary Engineering and CAPEX Budget Development, and Detailed Engineering to double the flow rate of both flour and sugar to several dough mixers in a snack bakery. The bulk silo room had 4 flour silos and 2 sugar silos, and was housed within the main bakery building. The controls system for the bulk unloading and transfer system, and the mixing operations were antiquated. The Bakery operation had experienced lost production time during the mixer cycles due to the limitations in the existing design of the Bulk Flour and Bulk Sugar delivery systems. The upgrades included scale bins, transfer bins, blowers, sifters, and piping. In a separate project, Morgan provided a safety assessment of the equipment and infrastructure to identify improvements needed for compliance with OSHA Dust Explosion Prevention standards.

Tortilla Line Commissioning - Process Troubleshooting

A major snack foods manufacturer was in the process of executing a capital project to install and commission a new Tortilla Chip operation, with the major unit operations designed and provided by the OEM. After 9 months of commissioning efforts by the client’s teams, the OEM, and industry experts performing troubleshooting, the line was only operating at 50% of the OEM’s expected rate. The client solicited technical support from Morgan’s SMEs in R&D and Processing Corn Tortilla Chips to conduct an initial operational and quality assessment and make short-term and long-term recommendations for equipment, materials, data collection, and SOP’s. Morgan quickly engaged a Sr Process Engineer and a Sr R&D Scientist to handle two major work streams in parallel, expediting the overall line operations turn-around.Morgan’s team conducted an initial Operational Assessment to better understand the capabilities and limitations of the equipment and raw materials. This led to optimized raw material specifications and replacement of undersized OEM designed equipment, and formulated methods and action items to maximize product throughput at each unit operation. Based on the operational limits identified in the assessment, Morgan determined that a line re-design was the practical solution to achieve target production rates in an expedited manner. Morgan’s SMEs provided recommendations for improvements, collaborated with the client’s team and the OEMs for the implementation of the modifications, and provided long-term operational support to implement the recommended changes.

ESL and Shelf Stable Technologies Co-Manufacturer Search

A client engaged Morgan to conduct an extensive, confidential search for US Co-Manufacturers capable of processing and packaging a new dairy-based nutritionally enhanced fluid milk product. The project was a fast-track effort to create a competitive advantage. Morgan’s scope was to identify solutions for either aseptic or extended shelf life (ESL) 2-liter packaging. Morgan assembled a team of Aseptic SME’s to conduct technical capability assessments over a wide range of options for primary package materials and configurations, keeping the client’s identity confidential throughout the entire evaluation process. Morgan investigated options including ESL Plastic and Paperboard with chilled distribution, Shelf Stable Plastic and Paperboard with ambient or chilled distribution, and combination technologies such as Bag-in-Box. Morgan’s team provided an overview of the Aseptic and ESL technology landscape and identified the commercially available technologies that met the rigors of processing protocols for consumer protection. Morgan gave the client frequent progress updates and presented very detailed information about each supplier’s and co-man’s capabilities in a summary table and call notes. The final comprehensive report delivered by Morgan’s team evaluated and recommended methods for processing and packaging the product. Upon approval by upper management, the client directed Morgan to create a formal presentation suitable for review by the executive leadership team.