INDUSTRY: Food & Beverage SERVICES: Construction Management | Project Management | Mechanical Engineering | Controls/Automation Engineering | Consulting Services – 3D Scanning /Airflow Study
ABOUT THE CLIENT
EAD is the trusted partner of a leading packaged food manufacturer that operates multiple U.S. facilities. We provide engineering and project and construction management services to ensure their critical infrastructure upgrades are delivered on schedule, under budget, and with minimal disruption to production.
PROBLEM TO SOLVE
Looking to increase production and make their bacon manufacturing process more efficient, our client sought to modernize their critical microwave bacon production line. They turned to EAD to deliver the engineering expertise and project oversight to demolish the existing line and replace it with a new, more efficient system. EAD was put to the challenge of installing the new line in an extremely small space between two active lines during a tightly restricted downtime window — without impacting adjacent systems or production output.
The project involved replacing the existing microwave line with a new AMTek Microwave system, including transmitters and cavities. EAD coordinated and integrated multiple vendor scopes, drawings, and deliveries, despite the limited availability of construction documentation. We also upgraded the existing Interleaver controls system in the packing area to enhance its overall performance and reliability.
APPROACH & SOLUTION
EAD developed a task-driven schedule that aligned with the client’s tightly defined production shutdowns, ensuring work progressed without interruption to production and nearby operating lines.
Integrated Planning & Coordination: We managed five subcontractors and three vendors responsible for demolition, equipment setting, electrical, roofing, fire sprinklers, and flooring. We coordinated and integrated vendor drawings and deliveries as the shutdown windows were defined by our client’s production schedules. We also overlaid our client’s shop drawings in 3D for clash detection.
3D Scan & Airflow Study: We conducted a 3D scan of the transmitter room, tying the existing first-floor 3D scan with an above-floor space to obtain a precise equipment layout. In addition, our airflow study of the facility production areas provided our client with the key data they needed to be able to balance their cooling systems in the future.
Engineering Support: We re-engineered the Interleaver controls system when the original vendor was unavailable—delivering updated panel layouts, component procurement, and coordinated installation/commissioning.
Collaborative Execution: We hit the project milestones despite limited client oversight and fostered a cohesive EAD–Monogram team environment by working in close collaboration with the project stakeholders.
RESULT & BENEFIT
EAD successfully delivered the project on schedule and 4.35% under budget, completing the demolition of the old line and installation of the new one within the planned four-day window. By project completion, our client had a new and seamlessly integrated microwave, exhaust, and slicer systems; more accurate equipment layouts; and confidence in EAD’s ability to manage complex installations under tight operational constraints.