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Coca Cola

Boiler replacement in 300,000sf production facility with no downtime to 24/7 operations

Engineer of Record

K. Scott Sine PE - H.T. Lyons

Date &  Location

2010 - Allentown, PA

Project Intensity



K. Scott Sine PE - H.T. Lyons


Food Processing


Owner CapEX

Annual Energy Savings

~15% - 20%+

Construction Manager

H.T. Lyons

Lead Engineer

Michael Cuchran ME - H.T. Lyons

Prime Contractor

H.T. Lyons


It was rare for The Coca Cola Company to outsource design/build unless project complexities required an innovative solution above and beyond the scope of traditional practices. Project focus was not on energy savings, rather how to overcome the challenges of replacing high-pressure steam boilers in a 300,000 sq. ft. facility, with no downtime to 24/7 operations permitted.

ENGIE MEP subsidiary H.T. Lyons was hired for all mechanical, electrical & plumbing scopes for the project, funded through owner capital expenditure (CapEx). GEMM Founder K. Scott Sine PE (Scott), masterplanned a solution incorporating new construction of an ~8,000 sq. ft. addition to house the high efficiency firetube boiler replacements and how to cross tie this equipment into the existing system.

Scott’s unique design afforded no downtime to 24/7 operations during installation and construction, with the additional benefit of achieving incremental 15% - 20%+ annual energy savings.

Coca-Cola Lehigh Valley Syrup produces concentrate for nationwide distribution to licensed Coca-Cola bottlers. The Coca-Cola Company is an American multinational beverage corporation with 2020 revenue in excess of $33 Billion and 80,000+ worldwide employees.

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