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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.
E Tech Group, one of the largest industrial automation firms in the United States, announced today that Sharon Koenig, CPA has been appointed Chief Financial Officer.
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