Aseptic Food Processing and Packaging
Project Summary
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Our Client: |
Worldwide producer and distributor of baby food and related food
products |
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The Project:
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Installation of $100M+ new aseptic food production and packaging lines
and associated utility systems and support equipment |
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APS' Mission: |
During construction and startup over a period of 16 months, prepare over
150 operations and maintenance personnel and area supervisors to safely
and effectively operate and maintain a complex new aseptic food
production and packaging facility |
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The Challenges: |
No
documentation or procedures existed to form a basis for training
development. No clear definition of operators’ roles and equipment
responsibilities. Low level of trainee experience relative to the
operation of the new processes and equipment. Multiple and
non-coordinated sources for equipment-specific technical information
retrieval from equipment manufacturers. Client-accelerated deadline for
commencement of line production. |
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APS' Approach: |
APS formed a project team of experienced industrial operations and
maintenance training specialists. The team worked with the client, the
principal architect-engineering firm, and the equipment manufacturers
throughout construction to obtain the technical information necessary to
design and develop training materials and procedures. APS' training
specialists researched each piece of equipment and the anticipated
operator tasks and responsibilities, and designed a task-based training
program to equip operators and technicians with the required knowledge
and skills.
APS designed and
developed training materials and technical documentation for the
following:
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Utility
systems (air, water, steam, nitrogen, etc.) |
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Raw
materials proprietary aseptic processing |
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Food batch
processing kitchens |
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Aseptic
food processing kitchens |
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Aseptic
packaging lines (form, fill & seal) |
For each of the
above areas, APS developed the following documentation:
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Operations
training manuals & instruction materials |
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Maintenance
training manuals |
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Standard
operating procedures |
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Preventive
maintenance procedures |
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Lockout-tagout
procedures |
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Job
performance aids |
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Job qualification checklists |
APS also
delivered classroom and hands-on training and assisted the client with
operator qualification assessments in each process area. |
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The Results: |
APS completed the development of all training and operations
documentation on time and under budget. All classroom and on-the-job
training was conducted just-in-time to support startup and initial
operations. The lines started up and reached target productivity ahead
of schedule. APS continues to assist the client with emerging training
and technical issues. |
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