Case Study

Dust Extraction Installation Within a Live Production Environment

Case Study

Dust Extraction Installation Within a Live Production Environment

Delivering improvements in live filling environments requires disciplined coordination and practical problem-solving. By aligning closely with production and leveraging local expertise, this project strengthened food safety controls without introducing unplanned downtime.

TEG Projects delivered the installation and commissioning of dust extraction systems on three glass fillers to mitigate food safety risks associated with crown application dust. The works were carefully coordinated within an active production environment, with installation and commissioning activities aligned to the evolving production schedule to maintain operational continuity while strengthening hygiene controls.

Bottle height extractor Project with TEG Projects

Client Information

The client, one of New Zealand’s leading breweries, produces several million bottles of beer annually across multiple high-volume glass filling lines. Operating at this scale demands precision, efficiency and stringent quality and food safety standards at every stage of the production process.

Goal

The objective of the project was to mitigate a food safety risk generated during the crowning process. When hundreds of crowns per minute pass through narrow metal channels, paint can chip from the caps, creating dust and paint specks.

This dust can accumulate in the filling machine, promote biofilm formation and potentially enter the product stream. To address this risk, dust extraction systems were proposed for installation on three glass fillers to remove airborne particulates at the source and strengthen overall hygiene control.

Why TEG Projects

TEG Projects’ project managers were seconded into the client’s engineering team to tender, install and commission the new dust extraction systems.

With many years of experience in the food and beverage sector, particularly on filling machines and quality-related projects, TEG brought practical knowledge of live production environments and associated risk controls. This experience supported structured planning, stakeholder coordination and delivery within a tightly managed operational setting.

Solution

The dust extraction units were procured from a German supplier, with TEG Projects coordinating their delivery and site integration. Upon arrival, a detailed audit of the equipment was undertaken to verify completeness, addressing prior supplier issues where components had been omitted from shipments. This proactive step reduced the risk of delays once installation commenced.

With no consecutive outage period available, installation works were carefully staged around the evolving production schedule. Local mechanical, electrical and automation contractors were engaged to deliver the installation and commissioning across the three glass fillers. Close coordination with production leads ensured that available windows were identified and optimised, allowing works to proceed without introducing unplanned downtime.

Commissioning strategy required particular consideration. The supplier’s proposal to send German engineers to site was deemed cost prohibitive. In response, a small team comprising local contractors and the client’s automation engineers undertook commissioning activities independently. Technical documentation was translated as required, and the systems were integrated without direct manufacturer attendance.

Throughout delivery, site quality, engineering and production leaders remained closely involved, ensuring the new dust extraction systems were effectively incorporated into operating procedures and aligned with existing food safety controls.

Challenges

The primary challenge was delivering installation and commissioning works without access to a dedicated shutdown window. The production plan was continuously evolving, requiring works to be carefully sequenced and closely coordinated to avoid disruption.

As mentioned above cost constraints associated with overseas commissioning support required the assembly of a competent local team capable of interpreting documentation, integrating the systems and completing commissioning without manufacturer presence.

Additionally, supplier reliability risks required proactive management, including thorough inspection of delivered equipment to avoid delays during installation.

Results

The dust extraction systems were successfully installed and commissioned without significant downtime to the filling machines.

In the first 3 months of use, the systems removed approximately 200 grams of dust from the crowning process. This has reduced the level of manual cleaning required by operators and lowered the risk of particulate contamination entering the product stream.

The project strengthened food safety controls within a live production environment while maintaining operational continuity.

Capabilities

Service Areas

Project
Management

Construction
Project
Management

Dust Extraction Installation Within a Live Production Environment