INDUSTRY: Biosolutions | SERVICES: Multiple Engineering Disciplines | Controls & Automation | Construction & Project Management
ABOUT THE CLIENT
Since 2012, EAD has supported the engineering and automation needs of a leading provider of bio-technology solutions for the food & beverage, household care, bio-agriculture, bio-energy, cleaning supplies, pulp & paper, distilling, enzyme production, and other industries.
PROBLEM TO SOLVE
Our client looked to expand their facility to meet the growing demand for their food-grade enzyme product line. As part of the expansion, they wanted to install five (5) new production fermenters, expand the site utilities, and add a new cooling tower cell. However, with a demanding, 24/7/365 production schedule, they were also faced with the challenge of ensuring the large project could be completed with minimal downtime.
APPROACH & SOLUTION
EAD was contracted to provide multidisciplinary engineering, project management, and construction management to support the addition of new production fermenters and downstream recovery unit operations as part of the facility expansion. We developed multiple engineering and project management strategies to limit downtime during the execution of the project. One way we minimized downtimes was through the use of parallel pipe runs and creative isometric design for the new pipe routing. We made extensive use of hot taps during the system tie-ins for the same purpose. We also developed creative solutions for the equipment routing and setting. By installing new line in the recovery to capture products that did not need filtration, and through re-engineering the controls around the CIP process, we even saved our client thirty minutes per cleaning cycle.
Since the project touched many areas of the plant and large crane lifts were needed to lift the fermenters, it was often difficult during the installation phase to keep the plant operating continuously at full capacity. EAD’s project management team worked closely with our client’s facility operations team, maintenance team, and contractors to install the new equipment, ensuring the installation of the fermenters was completed safely and without impacting production.
RESULT & BENEFIT
Through strategic safety planning, creative engineering, and managing communications between the multiple project stakeholders, we were able to ensure that the fermenter addition could be completed without downtime. The new system increased production at the facility by 30%. Our client praised the creativity and success of EAD’s engineering and management solutions in helping the facility meet their production goals during the complex facility expansion.