A Memphis facility identified an opportunity to reconfigure Line 2 to address ongoing scrap and reliability issues while improving access for maintenance and sanitation. The existing process included outdated equipment and access challenges that limited operational efficiency. Chief Engineering was engaged to develop the structural and platform design needed to support a new process layout and create a more functional, maintainable production environment.
The project centered around the installation of a new spiral conveyor system, suspended transfer conveyors, and associated GMP-compliant catwalks and platforms. Chief Engineering provided structural engineering, 3D scanning, modeling, and platform design services to ensure the new equipment could be integrated into the existing facility. The scope also included evaluation of the existing structural slab, vibration-isolated foundation design, model updates, and detailed engineering drawings suitable for fabrication and construction.
A major component of the project was coordinating the new equipment layout with the existing facility and OEM requirements. Early scanning provided the team with the site information needed to develop the design, while updated models helped coordinate the structural foundations and access platforms with the new process equipment. The resulting IFC documentation was developed to provide the client and contractors with a clear, constructible basis for installation.
Project timing presented several challenges. Two separate purchase orders were issued, creating a pause between the IFA and IFC phases. Once the second purchase order was issued, the client needed the IFC deliverables on an accelerated timeline, which coincided with the Christmas holiday period. Designer availability also required the team to adapt resources during the project, with additional internal support provided to keep the design moving forward.
Despite these challenges, the project was delivered on time and received strong client feedback. The project also established a positive relationship with a new client and demonstrated Chief Engineering’s ability to effectively manage changing schedules, multiple stakeholders, and evolving project requirements.
The project reinforced the importance of clearly managing client resources and expectations throughout multiple design phases. Different stakeholders were responsible for driving information during the IFA and IFC stages, and delays in issuing the second purchase order ultimately compressed the timeline for final deliverables. Through communication and adaptability, Chief Engineering was able to navigate these challenges while maintaining the quality and schedule of the final design.
The Line 2 reconfiguration demonstrates how engineering can support meaningful plant improvements beyond simply replacing equipment. By combining structural design, 3D scanning, modeling, and GMP-compliant access solutions, Chief Engineering helped create a more reliable and accessible process layout designed to support improved operations, maintenance, and sanitation.
