Enhancing safety and improving production processes with detailed piping schematics

The Challenge

During routine sampling of their water distribution system, a 300,000 square foot food processing plant discovered abnormal bacterial growth in several critical zones. These findings forced the plant to shut down key sectors of the operation, resulting in lost revenue. The remaining production systems required expensive modifications to meet customer demand, and the plant increased costly bacterial sampling to monitor levels and ensure safety.

Compounding the increase in costs and the lost revenue was the acute scrutiny from local and state regulatory agencies. The small bacteria created big headaches. Virtually every aspect of the plant’s operations was impacted, from product quality to employee safety to revenue and corporate reputation.

“Conscientious food processors and packagers take bacterial contamination very seriously, and for very good reason: it can occur anywhere, with virtually any kind of food product.”
– Glenn Adamus, HydroCorp Vice President of Operations

The Solution

The food processor was referred to HydroCorp, who had a team on site in less than 24 hours. “Conscientious food processors and packagers take bacterial contamination very seriously,” says Glenn Adamus, HydroCorp’s vice president of operations, “and for very good reason: it can occur anywhere, with virtually any kind of food product.”

HydroCorp’s team conducted a thorough survey of the plant’s water systems and created comprehensive piping schematics to identify vulnerable areas. In-depth water quality analyses of those vulnerable areas revealed a series of cross-connections between the potable and process water systems.

HydroCorp recommended strategically replumbing the affected portions of the system to improve flow, reduce stagnation, and eliminate cross-connections. The engagement, from first fieldwork to final report, was completed in less than 30 days.

The Result

The food processor readily implemented HydroCorp’s recommendations, and follow-up analysis confirmed the quality for both drinking water and product processing had significantly improved.

As a result, the plant was able to fully resume operations with the knowledge that their employees and customers, as well as their public water system, would be safe from contamination. Now, the plant has a robust water management program with up-to-date piping schematics, regular water quality analysis, and a documented maintenance regime that keeps their system safe and compliant.