Fast-Track Implementation of a New CIP and Steam Heating System for a Leading Food Manufacturer

Executive Summary

When the Clean-In-Place (CIP) system at a major global food manufacturer failed unexpectedly, rapid action was essential to prevent production downtime. Raptronic Process Engineering (RPE) immediately mobilised, reallocating resources to design and install a fully customised replacement under extreme time pressure — with the first stage commissioned between Christmas and New Year.

The project was delivered in two phases:

• Phase 1 – 2023: Design and installation of new CIP tanks under severe space and structural constraints.
• Phase 2 – 2024: Development of a bespoke steam heating system with a pre-assembled pumping and valve matrix, enabling fast installation and minimal downtime.

Project Background

The client’s CIP tanks had reached end of life, with leaks creating a serious risk of extended disruption. RPE responded immediately, reorganising priorities to deliver a reliable, long-term solution within an extremely compressed schedule.

Project Delivery

Phase 1: New CIP Tanks (2023)

• Challenges: Tight deadline, restricted access for tank delivery, strict structural load requirements, and very limited piping space.
• Outcome: New tanks, manufactured in part by RAP STEEL Production, were installed and commissioned between Christmas and New Year, ensuring uninterrupted production.

Phase 2: Steam Heating System & Valve Matrix (2024)

• Challenges: Highly customised design, multiple supplier iterations, and the need for safe operation within a confined footprint.
• Outcome: A fully commissioned steam system met all performance and safety standards. Off-site pre-assembly of pumps and valves enabled rapid on-site installation with minimal disruption.

Key Success Factors

The project succeeded thanks to:

• Transparent communication and flexible collaboration.
• 24/7 coordination between RPE and the client’s project team.
• Iterative design cycles adapted to evolving requirements.
• Dedication of RPE’s and RAP Steels’s engineering team and supplier network.

Conclusion

RPE turned a critical equipment failure into a showcase of agility and reliability in industrial project management. By applying an iterative, collaborative approach more often seen in software development, RPE delivered complex process solutions on time and under pressure — keeping production moving for one of the world’s largest food manufacturers.

RAP TRONIC PROCESS ENGINEERING, RAP STEEL PRODUCTION and RAP SYSTEMS – Industrial Automation are companies of RAP GROUP

To learn more about how RAP Companies can support the food and process industries, please visit:

www.raptronic.ro: Contact person: Bogdan Urdea: Sales Manager:  +40 726 222 843

www.rap-steel.ro: Contact Person: Marius Stefan Sales Manager: +40 736 106 410

www.rap-systems.ro: Contact Person Silviu Cucuian: + 40  723 350 982