Frutstix

Frutstix is a San Diego popsicle manufacturer, known for producing the "Sundae Shoppe" brand (Mango, Strawberry, Coconut) sold at Aldi, along with runs under its own Frutstix label. I joined as a maintenance mechanic for a few months as a bridge role before starting my master's program at UC Davis, working hands-on with the production equipment that kept the line running.

Day to day

My main responsibility was to ensure the continuous uptime of the automated popsicle production and packaging line. Starting with raw ingredients in a large blender, the line automatically shapes, freezes, and packages the popsicles into boxes, depositing them at a conveyor to a large industrial freezer for workers to store them away.

Each day, I would log into our CMMS (Upkeep) to execute work orders, document maintenance activities, and update the inventory of spare parts. After completing priority items, I would walk around the production room and observe the machines, identifying any areas that may require proactive maintenance to prevent downtime. Besides identifying wear and potential faults, I would study the machines to determine the root cause of different errors to better service the machines.

During the Summer months, I was trusted to be placed on the overnight shift alone and successfully maintained a near constant uptime. Even resolving a main-drive cylinder failure on my first day solo: disassembling, rebuilding, and reinstalling the cylinder to resume production.

I am experienced navigating electrical cabinets and reading electrical diagrams and schematics, regularly debugging control circuits, sensors, and pneumatic equipment. I sourced parts from McMaster-Carr and contacted vendors to find specific parts that fit production needs.

In addition to work on the production line itself, I also participated in facility maintenance and other large & small projects around the factory.

Production Floor Upgrades

Hot Water Pressure

Worked with the maintenance team to integrate a water pump after our tankless water heaters to improve pressure during high-demand production periods. Utilized an ultrasonic flow sensor to monitor instantaneous demand and trigger a contactor when it detects high-flow to activate the pump.

Production Line Spray Washer

During production of Mango popsicles, the pulp would regularly accumulate and cause the machines to pause operation to change-out the popsicle molds or risk the batter overflowing. Using spare parts, I drilled precise holes into a metal pipe, connected it to a hot-water faucet and creating a temporary jig to hold it in-line with the empty popsicle molds to serve as an additional spray-washer. This idea was later formally designed and professionally installed by welders.

Project Gallery

Cabinet Upgrade

Installed a rail to the top of a cabinet and replaced its doors with plastic curtains to make it easier for workers to store and retrieve their coats between breaks.

3D Printer SetUp

Helped my boss set up a 3D printer and printed a simple dovetail joint to demonstrate the printer's capabilities. The dovetail joints also served as inspiration for prototype components that could be removed in-place when placed on a holding rod, rather than requiring disassembly of the rod.

Outdoor Rust Sealing

Removed rust from an outdoor platform in sections, coating the cleared sections in a sealant to protect it from the damp, San Diego weather.

Forklift Accident

Towards the end of a long shift, I was gifted by a worker the pleasure of fixing a shutter door separating the loading dock from the factory interior. With a lot of elbow grease, I was able to reseat the metal shutters and seal the door on the same day and successfully replaced the shutters after ordering replacement parts.

Water Cooler Upgrade

After installing a reverse-osmosis system under the breakroom sink, I retrofit the water coolers to accept from the RO line rather than depending on water jugs. By testing the embedded system with a multimeter, I was able to replace the water pump with an electric valve with the same operating voltage provided by the PCB output.

Troubleshooting the Freezer HVAC Systems

Investigated a fault in one of the freezer systems and replaced the fan while lifted in a forklift cage.

Skills this drew on

Working with CMMS-driven workflows, diagnosing and troubleshooting mechanical, electrical, and pneumatic systems, and quickly learning new systems and techniques. I utilized a wide variety of hand and power tools and used creative solutions to proactively maintain systems and improve the factory quality-of-life.

Final Thoughts

I never really knew what to expect each day. Some days I'd spend the day solving problems before they become issues; other days I'd start my shift lying on a wet floor fixing plumbing underneath the machines. I always gave my 100% whether working out in the sun on a rusty platform or in a -20F freezer.