A leading food grade enzyme producer contracted with EAD to provide multidisciplinary engineering, project management, and construction management to support the addition of new production fermenters and downstream recovery unit operations at their facility. Our client wanted to expand their facility in order to be able to house two new production fermenters. As part of the project, they also wanted to set 14 ancillary tanks throughout the facility. The project included expansion to site utilities including a new cooling tower cell. EAD worked closely with our client’s facility operations team, maintenance team, and contractors to install the new equipment.
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 to keep the plant operating continuously at full capacity. However, through the use of strategic safety planning and managing the communications between the project stakeholders, EAD was able to ensure that the lifts could be completed without production downtimes.
EAD was also able to identify additional value-added scope items for our client during project close-out. New line was installed in the recovery to capture products that did not need filtration. We re-engineered the controls around the CIP process to save our client thirty minutes per cleaning cycle. Working in brownfield areas required creative equipment routing and setting. EAD was able to accomplish this through a thorough as-found condition analysis. The new pipe routing was completed through the use of parallel pipe runs and creative isometric design that minimized downtime. Another way that EAD mitigated downtime was through the extensive use of hot taps during the tie-ins. 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.
Client: Leading Food Grade Enzyme Producer
Location: North America
Market(s) Served: Pharmaceutical / Biological Solutions
- Construction Management Project Support
- Project Management Project Support
- Developed innovative solutions to install process equipment without impacting operations
- Maintained an incident free construction site for the entire duration of the project execution period
- Completed the project 14 months ahead of schedule and under budget
- Increased plant production by 33%