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Case Study • Food & Beverage Retail

Albertsons CIP System & Air Farm

State-of-the-Art System installed with zero unplanned downtime

Completed cleanly in exactly three brief outages. Detailed offsite prefabrication and strategic scheduling allowed full replacement with zero unplanned disruptions.

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Fast-Track Turnkey Execution Timeline

Active LineActive Clean-In-Place piping system integration
Outages Completed3 Outages

Active Plant Setup

Live Albertsons production operations

Surgical Accuracy

Engineered offsite preassembly stages

Contained Outages

All cuts conducted under 4 hours

Continuity Achieved

100% operational throughput preserved

Key Performance Successes

Critical Timelines • High Performance Results

3 Outages

Completed Outage Count

All installation phases achieved sequentially via three planned interruptions.

<4 Hrs

Maximum Planned Outage

Strict deadline control applied to ensure zero material or manufacturing delays.

0 Disruption

Unplanned Interruption

Facility preserved full commercial continuity with zero margin of error allowed.

100% Go

Continuity Maintained

Sanitized delivery lines fully active with next-generation utility systems online.

Case Context

The Challenge: Replace Critical CIP and Air Systems with Virtually Zero Downtime

Albertsons required a major utility modernization at their active production plant. They needed to fully replace aging Clean-In-Place (CIP) assets and optimize their foundational pneumatic Air Farm infrastructure.

At a high-volume retail supply facility, taking main production systems offline would cost substantial volume. DPS had only three planned outage windows, none of which could exceed four hours under any situation. Perfect, fast validation of connections was the key requirement.

DPS METHODOLOGY

Design • Build • Manage – Dynamic Alignment

Stage One

DESIGN

Detailed pre-planning and 3D modeling. Piping and valve matrixes modeled off-site to match plant ports perfectly and compress on-site structural modifications.

Stage Two

BUILD

Field prefabrication of manifolds, skid frames, and air conduits. Real-time physical rigging sequences pre-drilled to ensure connection drops were completed cleanly under deadline pressures.

Stage Three

MANAGE

Strict execution checklists tracking minute-by-minute progress. Successfully completed all three tie-ins on budget and ahead of time, ensuring Albertsons maintained full market operation with zero supply disruptions.

EXECUTION TIMELINE

Phased Modernization & System Integration

Turnkey Delivery Completion

  1. Pre-Outage

    Engineering & Prefabrication

    Offsite fabrication of CIP skids. Material procurement set and local field resources fully mobilized.

  2. Outage 1

    < 4 Hours

    First tie-in completed. Primary CIP lines cut over and initial process piping validations released cleanly.

  3. Outage 2

    < 4 Hours

    Air Farm manifolds integrated and pneumatic line pressure checks executed concurrently without delay.

  4. Outage 3 🎉

    < 4 Hours

    Final integration loop finalized. System validation and dry run cycles safely completed inside the final planned limit.

  5. Post-Outage

    Full Integration

    New utilities running at full commercial capacity with 100% operational supply chain maintained.

CLIENT VOICE

“DPS executed this critical upgrade with incredible precision. We experienced zero unplanned downtime across three separate outages. Every minute truly counted — and they delivered.”

Facilities Engineering Manager

Albertsons Companies

IMPACT HIGHLIGHTS

Total Outages Scheduled
3 (all < 4 hrs)
Unplanned production loss
Zero
Piping Integration efficiency
100% Successful

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