Case Study Torresan Estate – Automated Filtration System

The main challenge for Torresans was the significant strain on staff time and the resulting impact on their quality of life, caused by the manual and undersized filtration skid in use. Due to the existing filtration system lacking automation, at least one staff member needed to be present for every operation to manage the manual processes.

Additionally, the absence of remote access further increased the demand for on-site personnel. With the existing skid at capacity and the Line 2 filler being upgraded, there was an urgent need for a high-flow filtration solution.

The proposed solution for enhancing the competitiveness and brand equity of the wine producer involved the implementation of a state-of-the-art Automated Filtration System (AFS) tailored to efficiently filter wine in alignment with the new filler’s specifications. The system offers three filtration options—200 µm stainless mesh, 5 or 10 µm polish, and sterile filtration—ensuring all packaged wines undergo rigorous filtration processes, with mesh filters serving as a final precaution. The duplex design accommodates both white and red wine production, while the sterile filtration train incorporates advanced cartridge filters to maintain high process efficiency and integrity.

Critical to the system’s operation are its automated features, including real-time monitoring, remote access via smartphone, and seamless integration with existing CIP and filler systems, all controlled by a sophisticated PLC. This automation significantly reduces manual intervention, enhances production efficiency, and minimises downtime. The design prioritises the preservation of wine quality, using nitrogen purging to minimise oxygen exposure and wine loss.

Overall, this innovative filtration solution not only streamlines production but also reinforces the wine producer’s commitment to quality and operational excellence, ultimately bolstering their brand reputation in a competitive market.

A time-lapse video of the Filtration System in operation, spanning three hours of operational time condensed into 1 minute of footage, to give an idea of the system’s autonomous function.

The new Automated Filtration System (AFS) achieved remarkable outcomes:

• Increased Production Speed: Enhanced filtration capacity allowed for faster processing alongside the new, larger filler.
• Extended Consumable Life: Larger housings improved filtration efficacy and longevity of consumables.
• Significant Time Savings: Remote access reduced the need for on-site staff, enhancing their quality of life.
• Future-Proof Design: Programmable PLC allows for easy integration of new functionalities, as needed.
• Reduced Manual Oversight: Automation lowered user input requirements, enabling staff to focus on other critical tasks.
• Minimised Downtime: The duplex housing’s prefilter duty/standby configuration ensured continuous operation with fewer interruptions.
• Efficient Integrity Testing: In-situ testing streamlined quality assurance while saving staff time and ensuring traceability.
• Comprehensive Monitoring: The system logs flow, pressure and conductivity data, enabling real-time analysis for improved decision-making.