Solutions Applied in Demanding Industrial Plants.

The Challenge

Modernize the CIP (Cleaning In Place) system of the ERCA 01 machine, automating the cleaning process to increase operational reliability, reduce manual interventions and ensure repeatability of sanitation cycles. The project required the fabrication and installation of a sanitary manifold, execution of tie-ins on a live production line, and welding following the rigorous standards of Lactalis as well as ASME BPE and ASME B31.3, preserving the sanitary integrity of the process.

The Montech Solution

Montech was responsible for carrying out the mechanical assembly required for CIP system automation, including:

Fabrication and installation of the distribution manifold for CIP system automation;

Execution of mechanical tie-ins according to production shutdown availability;

Sanitary TIG welding with pure argon shielding, meeting Lactalis standards and ASME BPE and ASME B31.3 requirements;

Replacement of leaking piping and supply of required application materials;

Execution planning with a specialized team consisting of a foreman, industrial pipefitters, qualified TIG welders and assembly helpers, ensuring safety, quality and traceability throughout the project.

Results

The system modernization delivered an infrastructure prepared for automation of the ERCA 01 CIP cycles, increasing the reliability of cleaning operations, standardizing sanitary tie-ins and enhancing the operational safety of the line. The execution followed the highest standards in welding and sanitary assembly, enabling future integrations with the automation system and contributing to greater production availability and efficiency.

The Challenge

Transform the Decor 02 filling line, expanding its production capacity from 2 to 4 containers through a complete electromechanical, mechanical, electrical, automation and start-up upgrade. The project required the integration of new tanks, pumps, product piping, CIP and utilities, installation of automatic valves, laminar flow systems, metal platforms and upgrades to the electrical and automation infrastructure, ensuring plant operational continuity and meeting the stringent sanitary standards of the food industry.

The Montech Solution

Montech was responsible for the complete electromechanical assembly of the project, including:

Fabrication and installation of sanitary piping for product, CIP, peracetic acid and sterile air;

Installation and positioning of pumps, tanks, automatic valves and process equipment;

Fabrication of supports, manifolds and stainless steel platforms;

Electrical assembly, infrastructure, cable routing, AS-i industrial networks, instrumentation and panels;

Automation development, programming of manufacturing routines, CIP, sterilization, filling, commissioning and start-up;

Inspections, operational testing and line start-up monitoring, ensuring performance, reliability and process quality.

Results

The project execution enabled the expansion of Decor 02’s production capacity from 2 to 4 containers, significantly increasing line productivity. The entire installation was delivered in compliance with Lactalis technical and sanitary standards, with fully integrated mechanical, electrical and automation systems, providing greater operational efficiency, process reliability and production safety.

The Challenge

Implement a new Primary WFI (Water for Injection) Loop intended to supply pharmaceutical systems G and H, ensuring continuous operation, full process traceability and compliance with pharmaceutical industry requirements. The project involved sanitary fabrication, installation of tanks, piping, valves, pumps, instrumentation, thermal system, complete automation and compliance with 21 CFR Part 11 requirements.

The Montech Solution

Montech carried out the complete fabrication and installation of the system, including:

Fabrication and assembly of the primary loop in sanitary stainless steel;

Installation of WFI storage tanks, recirculation pumps, heat exchanger, sanitary valves and instrumentation;

Fabrication of supports, manifolds, pneumatic distribution and process tie-ins;

Sanitary TIG welding with high-purity argon atmosphere and finishing in compliance with pharmaceutical standards;

Development of the automation system using Siemens PLC, HMI and SCADA supervisory, including PID control, thermal and chemical sanitization recipes, monitoring of temperature, pressure, TOC, conductivity, flow rate and loop velocity, as well as electronic traceability and user management in compliance with 21 CFR Part 11.

Results

The project delivered a highly reliable Water for Injection (WFI) distribution system, operating in continuous recirculation mode with automatic control of critical process parameters and full compliance with pharmaceutical industry regulatory requirements. The result was a robust, safe and traceable solution, prepared to ensure the quality of water for injectables, increase operational reliability and support future client validations and audits.