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Modular Process Case Studies

Food Plant Expansion Capitalizes on Modular Build of Sanitary Batching and Blending Systems

Client: International Food Products Manufacturer

Industry: Food & Beverage

Overview: A pair of EPIC process engineers oversee installation of a modular food processing plant

International Food Products was moving and expanding operations to a new $20 million facility in St. Louis, MO.  They approached EPIC about providing pre-engineered sanitary blending skids equipped with multiple batch mixing systems for both liquid and powder products. EPIC designed, built and integrated the sanitary skids. In addition, EPIC integrated and expanded seven liquid and powder packaging lines.

Key System Features:

  • Designed to meet Title 21 cfr Part 110 cGMP guidelines
  • Turnkey batch blending systems
  • Liquid process and packaging lines
  • Sanitary system fabrication
  • Utilities expansion and integration
  • Process facilities design
  • Construction management

Core Challenges:

  • Integrating existing equipment into the new facility
  • Balancing new system design/build schedule with installation and integration of existing equipment
  • Moving equipment from an old facility to a new location
  • Fast track design/build schedule
  • Training of new employees on expanded manufacturing capabilities



Solution Summary

To meet growing market demand, International Foods purchased the brownfield site of a closed Ford Motor Company plant in St. Louis. Partnering with EPIC Process Systems, they built a new facility and expanded production for both liquid and powder food product lines.  The processing and pack out portions of this project were the heart of the $20 million expansion.

Starting early in the project planning process, EPIC’s project management set the direction for process facilities design and associated power and utilities. EPIC completed process and physical design for each of the processing areas, efficiently using space to allow room for future expansions within the facility. All process and packaging equipment were required to comply with food and beverage sanitary requirements Title 21 CFR, Part 110 cGMP guidelines.

While site and facilities construction was underway, process system fabrication at EPIC’s sanitary fabrication plant was occurring simultaneously. Process systems were constructed as self-contained modules. Finished modules were shipped to the International Food Company plant, followed by a fast startup within three days of arrival.  EPIC’s offsite modular build approach was critical to the success of meeting a stringent project schedule.  Each sanitary batching and blending system went through in-house, Factory Acceptance Testing (FAT) to ensure a trouble-free start-up during installation.

EPIC Project Management coordinated all utilities installation and integration on the heels of facility completion to eliminate potential schedule creep on process system installation. A team of EPIC’s in-house automation engineers was on site throughout installation and commissioning. Their presence helped ensure the process and packaging systems were running at specified parameters. They also assisted in training plant personnel on all new operating systems associated with the new plant equipment.

The collaborative project resulted in a successful startup, allowing International Foods to increase production, meeting demand for their growing product lines.

Impact:

  • International Foods successfully start up at the new facility was on time and budget
  • Product offerings and production capacity nearly doubled for the company
  • Higher automation in new systems allowed better tracking and quality control of products

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EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077