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An American biotechnology company knew their legacy control systems were approaching end-of-life, making an upgrade essential for their site in California. E Tech Group provided several control system upgrades to their automated systems.
An American biotechnology company knew the truth – their vintage control systems were approaching end-of-life, making an upgrade essential for their site in California. Our client was grappling with key questions such as:
The company recognized the issues they had with their aging systems, their own limited resources to dedicate to this evaluation, and the one thing they themselves could not do: have an outsider’s perspective with an industry-wide viewpoint.
The client made the decision to bring in that outsider perspective and partnered with E Tech Group for their controls platform retrofit. Our team of automation engineers brought with them 30+ years of biopharma experience, as well as knowledge of automation platforms and biotechnology systems. For a project of this importance, creating a strong partnership between client and consultant was crucial.
Our team included seasoned engineers who have experienced large-scale control system platform selection. We’ve also experienced conversion projects as owners and supported similar decisions for other biopharma clients as consultants. This allowed us to bring unique points of view to the project scope, coming in with an understanding of the specific needs of biotech automation.
E Tech Group and the client’s team went through a process of requirements definition and user group meetings with the company’s current and future site and global needs in mind. E Tech Group supported workshops with all of their stakeholders:
To ensure the facility-wide control system improvements provided our client with the resources and ROI to continue to grow, our automation team brought several leading control system supply partners into the discussion.
The E Tech Group team challenged the biotechnology company to think beyond basic requirements from a technical and business perspective. Engaging the team together in workshops enabled cross-functional groups to learn about how others within the client’s company would be using the system. Our team was uniquely positioned to objectively facilitate an effective conversation and align their various perspectives through industry knowledge and expertise.
At the conclusion of the process, multiple control system platform solutions were evaluated against the newly defined requirements – the team considered PLC/HMI and DCS-based systems and single-vendor/multi-vendor PLC/HMI platform options. E Tech Group worked with the internal stakeholders at the company to objectively evaluate the options and assess how the different platforms could best support the business needs.
In collaboration with our client, E Tech Group supported the development of a decision matrix to quantify the analysis of the different platforms. Additionally, we worked closely with the decision analysis team to develop financial and statistical models to help them determine the best option from a technical, financial and risk perspective.
Through this process, the stakeholders reached a unanimous decision on the future platform for the site. The client, E Tech Group and the control platform vendor continued to collaborate to develop the long-term roadmap to support the upgrade/conversion of the site to the new platform. The updated control system allows the client to optimize current operations as well as lay the ground work for them to reach future goals and industry benchmarks.
A steel company came to E Tech Group for help with their cold mill line automation. Improvements to the client’s cold mill yielded measurable financial savings by reducing defects and improving the safety of their automated processes.
E Tech Group was hired for a large project by a leading steel company to increase throughput and safety on the customer’s six-stand cold mill line. Additional project goals were to reduce head and tail off gage, reduce inner stand strip breaks, reduce electrical downtime, and improve safety.
The solution to the client’s goals would require creativity on the part of the system integrator and open communication with the steel company. E Tech Group worked closely with the client from start to finish on this targeted control system update.
E Tech Group conducted a mill drafting study to determine HP and speed limitations, reviewed the mill model, and set up proper procedures. E Tech Group control system engineers also conducted an equipment audit to determine the failure rate and root causes, and then began implementing the audit’s recommendations.
E Tech Group’s automation professionals implemented monitoring and tuning of the inner stand tension, MG set stand one custom 12 pulse drive to fit on existing gen base, screw down clutchless control, and regulated the voltage to the speed reg.
Additionally, a safety study was performed and the recommendations implemented. Installation, startup and commissioning were then performed.
This control system integration resulted in the client experiencing tangible results immediately upon implementation. This successful project proved the value of custom automation system upgrades:
This resulted in a quick ROI for the client, who now has an integrated control system that allows them to closely monitor processes on the cold mill to improve and ensure the quality of their products. E Tech Group’s automation solutions for metals clients employ strategic design and the best in automation technology today to keep manufacturers ahead of the competition curve, facilitating future growth and success.
In late 2019, Boochcraft Brewery, a California-based specialty brewing company located in Chula Vista, was excited to see their consumer base enjoying the brewery’s hand-crafted kombucha, so much in fact that sales were growing exponentially throughout California. This growth expedited the need to expand the company’s operations beyond its existing single location to keep up with the welcome demand. It was then that they purchased a second warehouse and contracted with E Tech Group to develop the best design, controls, and solution necessary to automate the new facility’s kombucha brewing temperature control process and increase production.
E Tech Group initially ran program simulations and Factory Acceptance Tests (FATs) on the existing 20 tanks. The tests were conducted to identify and correct potential problems or other technical issues that could impede the new operations. In this initial two-month phase, the team also researched the industry’s technology, inspected the newly purchased warehouse to determine its operational suitability and focused on automating the heating and cooling temperature controls with built-in redundancy to ensure they did not lose entire batches of kombucha should any part of the system go offline during the brewing process.
Upon testing completion, the project team began automating and implementing the juicing system. This six-week effort involved adding a juicing system for citrus and other produce. Once the automation was completed, the juice was transported into juice tanks for storage and later infused with the kombucha.
In the final phase of the project, the team increased the number of 100-barrel tanks—each accommodating roughly 3,100 gallons —from 20 to 40 over a six-week period, thereby doubling the amount of brewing capacity.
E Tech Group conducted FATs at each phase of the project prior to commissioning to the next phase to ensure all systems and processes were installed, tested and operationally functional.
As a Control System Integrators Association (CSIA)-certified business, E Tech Group’s focus on best practices ensures the company sets and meets the highest standards for its employees and business operations. This industry-standard project management approach enabled the team to expand and fully automate the kombucha brewing process, all while ensuring system redundancies and quality controls were built into the solution.
Expanding the brewery’s operations at the second site resulted in increased kombucha production and a reduction in the brewery’s labor costs, as they were able to re-allocate employees to other parts of the business. This allowed the company to ensure product availability and ultimately grow operations outside California.
Relying on E Tech Group for help with our expansion was easily one of the best decisions we have made as a company. They were not only knowledgeable but also instrumental in getting our capacity up and running both within budget and on time. The best part of E Tech Group was not only the experience working with them during the project but also the support they offered afterward when small hiccups arose. Andrew and the rest of the team are incredible, and we’re definitely looking forward to working with them in the future on new projects!”
Bryan River, Chief Operating Officer
Boochcraft Brewery
Fontaine formerly served as Chief Commercial Officer and Executive Vice President of Parcel, Consumer Products and Food & Beverage. In his new role, he will also oversee E Tech Group’s Mission Critical Center of Excellence, previously led by Troy Miller, who leaves to pursue a venture outside of the automation industry.
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