Albertsons
CIP System & Air Farm
Completed cleanly in exactly three brief outages. Detailed offsite prefabrication and strategic scheduling allowed full replacement with zero unplanned disruptions.
Critical Timelines • High Performance Results
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.
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Outages strictly limited — Absolutely three brief cuts allowed.
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Time limits enforced — Strictly max 4 hours per window.
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Running operations — Standard dairy and food flow active.
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Hygienic conditions — Stringent clean room and valve codes applied.
DPS engineered, prefabricated, and staged all piping manifolds off-site. Meticulous planning of every process step, back-up system, and utility swap protected active product supply lanes seamlessly.
Design • Build • Manage – Dynamic Alignment
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.
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.
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
Engineering & Prefabrication
Offsite fabrication of CIP skids. Material procurement set and local field resources fully mobilized.
< 4 Hours
First tie-in completed. Primary CIP lines cut over and initial process piping validations released cleanly.
< 4 Hours
Air Farm manifolds integrated and pneumatic line pressure checks executed concurrently without delay.
< 4 Hours
Final integration loop finalized. System validation and dry run cycles safely completed inside the final planned limit.
Full Integration
New utilities running at full commercial capacity with 100% operational supply chain maintained.
Installation & Integration Phase Images
“DPS executed this critical upgrade with incredible precision. We experienced zero unplanned downtime across three separate outages. Every minute truly counted — and they delivered.”
Connect With our CIP Upgrade Architects
Let’s map out how DPS can deliver your next facility modernization, line expansion, or complex process plant retrofit with absolute timing precision and zero commercial lag.
