EPIC designs and builds custom batching systems with a focus on minimizing downtime for your production lines. We are experienced project engineers with many years of in-plant experience. We reduce changeover time and deliver capital-efficient solutions in the fastest time-to-market for both sanitary and industrial batch mixing, reacting, coating and centrifuging systems.
We are experienced at fully extracting your technical, operational and commercial specifications for batching plant design. Our process for building turnkey batch systems includes:
- Utilizing a unique Front-End Engineering process to ensure the proper steps are taken during project scope development
- Following our proven design/build process that has resulted in over 420+ successful startups by taking turnkey responsibility for delivering a high-quality, ready-to-run system for all our customers.
- Modular design/fabrication that reduces traditional downtime through parallel construction and results in cost-savings, increased safety and faster project delivery. Learn more about the benefits of modular…
Are you looking to concurrently add raw materials or improve the accuracy of your batching plant design? An EPIC batch mixing system automates highly accurate ingredient additions and focuses on repeatability. Mass flow meter charging reduces batch cycle times, allowing concurrent raw material addition. Learn more about batch mixing and blending systems from EPIC…
We provide a reliable, safe solution based on careful modeling of reaction kinetics and agitation methods during design. EPIC’s experienced chemical engineers combine your specific unit operations into single batching systems, and are well versed in safety device & safety interlocks for batch reactors. Learn more about batch reactor systems….
From simple stirring to process intensification using ultrasound technology, EPIC delivers expert emulsion systems that efficiently mix your dispersed phase into your continuous phase. Whether your process calls for regular emulsion, micro-emulsion or nano-emulsion, EPIC will provide a proven system with long-term ROI and consistent output. Learn more.
Uniformity across your automated spray coating system depends on: accurate metering, proper substrate turnover and sufficient spray times. Our expertise is automating coating systems to deliver a precise amount of coating material that matches your manufacturing cycle time. Learn more about automated coating systems…
Achieving your desired solid-liquid separation via an automated centrifugal system requires a careful study of force, desired degree of separation and the properties of the two substances being separated. EPIC will help you select, integrate and automate the correct equipment for your batch mixing application, avoiding expensive repairs or equipment failure after only a few runs. Learn more about centrifugal systems….
Batch Manufacturing Case Studies
Multi-Skid Sanitary Batch Mixing Module
A multi-skid batching plant process for water, fragrances, antibacterial and dust control chemicals was designed and integrated for a Fortune 100 pet care client. The sanitary USP grade tank mixing system was designed as a series of modular skids. The platform and modular design allowed easy access to chemical batching skids, equipment and system controls.
Key Features: Batch mixing systems, USP grade system, modular skid, antibacterial, dust control chemicals.
A batch reactor system for a proprietary ion exchange reaction allowed successful scale-up of an R&D system. EPIC designed the unit with limited knowledge of the end product. By understanding the sequence of operations, and not the full details of the client’s process, we were able to fulfill the client’s need for confidentiality. The basic process involved several chemicals mixing and then run across a catalyst. The catalyst allowed ions to be exchanged and altered the chemical make-up of the mixture. Read the full chemical pilot plant case study…
Key Features: Catalytic reactor, scale-up of R&D process, low flow, highly corrosive, effluent treatment system, Teflon lined piping, tight footprint
Dog Food Flavor Coating System
A dog food company needed a way to test new flavor combinations that allowed for exact recipe retention and recall. The system needed to be flexible for testing many combinations, while making small changes in individual ingredients. EPIC designed, built and installed a batch spray coating system that accurately weighed both liquid and dry ingredients, had a recipe management and data collection system, and a sanitary pump/spray nozzle for highly accurate (+/- 0.25%) coating.
Key Features: Sanitary batch spray coating system, highly accurate spray (+/- 0.25%), sanitary design/build focused on ease of cleaning, Recipe management system, liquid & dry weigh systems
Centrifuge Batching System to Remove Solids from Liquid Product
An ethanol plant required a process to remove solids from liquid product in large batches. EPIC installed a centrifuge batching system that was designed to separate corn solids from liquid product using a high-velocity Westphalia centrifuge. The system was installed in the existing plant and mounted on a concrete pad within a sturdy steel structure. A crane was integrated into the system, to allow operators to lift the bowl out of the centrifuge.
Key Features: Westphalia centrifuge, mounted crane to lift centrifuge bowl, PLC controls
“We chose EPIC based on their strengths in several areas and they did not disappoint. They have first-rate technical know-how. EPIC did an excellent job in designing our tank farm and blending system. The design included explosion proof design since there were flammable chemicals involved. It included 11 blending tanks for 3 different finished products and a tank farm to house 9 different bulk chemicals.”
– Engineering Manager | a multinational manufacturing company