How Embedded Controls Engineering Helped Ocean Spray Increase Throughput by 30%
Closing a Critical Staffing Gap with Embedded Automation Expertise
In today's highly competitive food and beverage manufacturing environment, maintaining reliable operations requires skilled controls engineers who can support automation systems, optimize production processes, and drive continuous improvement initiatives.
When Ocean Spray faced the loss of its lead controls engineer during an existing engineering staffing shortage, critical automation projects began falling behind. With production demands continuing to grow, the facility needed immediate controls engineering support to reduce project backlogs, improve reliability, and maintain operational performance.
By partnering with Pieper Automation, Ocean Spray gained access to experienced embedded controls engineers who quickly integrated with the plant team and helped deliver measurable results, including a 30% increase in throughput and improved plant reliability.
The Challenge: Limited Controls Engineering Resources Threatened Progress
Ocean Spray's facility produces large volumes of juice and cranberry sauce products for retail, food service, and school markets. After losing a key engineering resource, the plant faced a growing list of automation, controls, and reliability projects that needed attention.
Without dedicated controls engineering support, the facility risked:
Delayed automation initiatives
Increased project backlogs
Reduced production efficiency
Safety and infrastructure improvement delays
Limited capacity to support future growth
The organization needed a partner that could provide immediate technical expertise while working seamlessly with internal stakeholders and existing operations.
What We Delivered
Pieper Automation provided embedded controls engineering services, placing experienced automation specialists directly within the Ocean Spray team. The engagement began with full-time, on-site support and later transitioned to a flexible part-time model as the facility's needs evolved.
Working as an extension of the plant's engineering department, Pieper Automation collaborated with operations personnel, maintenance teams, and external vendors to prioritize and execute high-impact projects focused on:
Automation system improvements
Process optimization
Safety enhancements
Reliability upgrades
Controls infrastructure modernization
This embedded approach allowed the facility to quickly restore engineering capacity without the delays associated with recruiting and onboarding internal resources.
Key Automation and Controls Improvements
Throughout the engagement, Pieper Automation completed a variety of controls and infrastructure projects designed to improve plant performance.
Controls & Infrastructure Upgrades
The team implemented several critical modernization initiatives, including:
Upgrading legacy PowerFlex drives to PowerFlex 525 drives
Implementing VFD control for the Fuji conveyor system
Restoring and configuring Rockwell AssetCentre for backup and change management
Updating control system infrastructure to improve long-term maintainability
These improvements enhanced system reliability while providing better visibility into plant operations.
Process Optimization
To improve production efficiency and consistency, Pieper Automation focused on key process control enhancements, including:
PID tuning on the Line 1 pasteurizer
Optimization of juice recovery processes
Troubleshooting and resolving CIP system faults
Replacement of critical instrumentation and flow measurement devices
These efforts helped stabilize processes and reduce operator intervention while maximizing production performance.
Safety and Operator Visibility Improvements
The team also delivered several important safety and monitoring upgrades, including:
Standardized emergency stop implementation
Ammonia detection alarming
Boiler system integration with operator HMIs
Updated iFIX screens and visualization improvements
By improving visibility into critical plant systems, operators were equipped with better information for decision-making and faster response times.
The Results: Increased Throughput and Improved Reliability
The combination of restored controls engineering capacity and strategic automation improvements delivered significant operational benefits.
Key results included:
30% Increase in Throughput
Between March and July 2025, the facility achieved a reported 30% increase in product throughput, demonstrating the impact of targeted controls and process improvements.
Reduced Project Backlog
With dedicated controls engineering resources focused on execution, Ocean Spray significantly reduced its backlog of automation-related projects and completed long-standing improvement initiatives.
Improved Reliability and Performance
The facility experienced more consistent line performance, improved process control, and fewer operator interventions, helping support reliable production schedules.
Enhanced Safety and Visibility
New controls, alarming systems, and improved HMI functionality strengthened the plant's safety posture while increasing visibility into critical utilities and operating conditions.
Additional Capital Investment
The operational improvements were substantial enough that Ocean Spray's corporate leadership approved additional capital investment for the facility, reinforcing confidence in the plant's future growth.
Why Manufacturers Choose Pieper Automation for Embedded Controls Engineering
Manufacturers often face challenges filling specialized automation and controls engineering roles. Pieper Automation helps bridge those gaps by providing experienced engineers who can integrate directly into production environments and begin delivering value immediately.
Ocean Spray selected Pieper Automation because of its:
Deep process-industry expertise
Flexible embedded resource model
Advanced automation and controls knowledge
Collaborative, team-oriented approach
Proven track record of delivering measurable operational improvements
By acting as an extension of the customer's engineering organization, Pieper Automation helps manufacturers solve staffing challenges while accelerating automation initiatives and improving plant performance.
Looking for Embedded Controls Engineering Support?
Whether your facility is facing a controls engineering staffing shortage, managing a growing automation project backlog, or pursuing production optimization initiatives, Pieper Automation provides the expertise needed to keep critical projects moving forward.
Our embedded controls engineering services help manufacturers improve reliability, increase throughput, reduce downtime, and maximize the return on automation investments.