Project Overview
A processing facility identified a critical need to replace an aging flaker system that was no longer supported by the original manufacturer. The outdated equipment posed operational risks and potential safety concerns for personnel, making replacement essential to maintaining both productivity and a safe working environment.
To support this upgrade, engineering services were required to design the necessary infrastructure for installing a new flaker system. This included developing construction-level designs for hoppers, chutes, and structural supports to ensure the new equipment could be safely and efficiently integrated into the existing facility.
Project Objective
The primary objective of this project was to deliver construction-ready engineering documentation to support the installation of a new flaker. The design needed to account for existing site conditions while ensuring proper material flow, structural integrity, and safe operation of the upgraded equipment.
This required careful coordination between process design, structural engineering, and installation considerations to ensure the final system would perform reliably under real-world operating conditions.
Scope of Work
The engineering scope included:
- Design of new hoppers and chutes to support material handling
- Structural design of equipment supports for the new flaker
- Development of construction-level drawings and documentation
- As-built modeling to align new designs with existing facility conditions
- Coordination with installation teams to address constructability requirements
All deliverables were developed to support a smooth transition from design to installation, minimizing disruptions to ongoing operations.
Project Execution & Coordination
The project required close coordination across multiple stakeholders, particularly as client-side leadership transitioned during execution. Despite changes in the primary point of contact, communication remained consistent, allowing the project to progress without delays.
As-built modeling was completed in-house to ensure design accuracy and alignment with existing structures. This step proved critical in identifying potential conflicts early and reducing risk during installation.
During the design phase, minor challenges were encountered, including limited scan data that affected anchor bolt placement. This issue was quickly resolved through design adjustments, preventing downstream construction delays. Additional coordination during installation ensured that structural support requirements—such as beam load ratings—were properly addressed.
Results
- Delivered 100% on time
- Maintained high client satisfaction
- Successfully provided construction-ready documentation for equipment installation
- Supported safe and efficient integration of new equipment
The project demonstrated strong execution despite coordination changes and minor design challenges, ultimately delivering a reliable and constructible solution.
Conclusion
The new flaker installation project provided a critical upgrade to aging equipment, improving both operational safety and long-term reliability. By delivering detailed, construction-ready designs and maintaining strong coordination throughout the project lifecycle, the engineering team enabled a seamless transition from outdated equipment to a modernized system.
This project highlights the importance of combining accurate site data, thoughtful structural design, and responsive communication to successfully execute equipment replacement projects in active industrial environments.
