Blending Center for Excellence

The Client has been completing initial feasibility work for a capital project to develop a blending operation named the Blending Center of Excellence (BCOE), located at their Belcamp Brass Mill location.

The current Belcamp blending operation does not accommodate value‐added complex blends, including, but not limited to, blends containing allergens PBP (plant‐based proteins) and HIS (high intensity sweeteners). Addition of complex blends is one of the Client’s strategic growth-initiative for food systems in the United States and Canada. This new operation will support both existing production requirements as well as the expanded complex blends product line.

Key performance goals included the following:

• Blending line capable of 11MM lbs of product per year
• Manufacturing area shall be cGMP compliant
• BCOE shall conform to the Client’s Engineering & Construction Standards
• Blending batch‐size 3,500 lbs, with flexibility to produce 1,500 lb batches from same equipment
• Throughput minimum 1,750 lbs/hour, design for 2,000 lbs/hour
• Goal of operation to maintain 80% plus uptime
• Anticipated Equipment footprint Area (BMOC Set‐up /Thermal Blending Area)
• Design in Accordance with Food Safety requirements (screens, magnets, metal detection)
• CIP Required – to meet quality validation specifications
  a. Between Allergen products runs
  b. Between non‐allergen product runs
• Packing & sealing with automatic bag sealing designed to fill 40‐55 lb bags and bulk bags (1000‐ 2000 lbs)
• Plan for a second 11 MM lbs/year blending line. Conceptual Equipment Arrangement only

TAI provided multidiscipline engineering and architectural design services – as well as comprehensive project management – for the development of preliminary design documents to support the Client’s project. TAI adhered to the submission requirements for the Capital Project Request including the following:

• development of PFDs;
• general equipment arrangement preparation;
• process and utility equipment selection and preliminary specifications;
• utility requirements;
• ancillary equipment definition;
• process description; and
• preliminary electrical power design to meet the goals of the BCOE installation.

The preliminary design included consideration for raw material handling and storage, set‐up (kitting), blending, finished goods packing and sealing, finished goods storage, equipment cleaning, CIP and changeover.