Brownfield Manufacturing Facility Transformation

Brownfield Manufacturing Facility Transformation

Industry: Consumer Packaged Goods
Project Type: Civil & Structural | Architectural | Process Engineering | Mechanical Engineering | Power | Piping | Instrumentation Engineering | Electrical Controls | PLC & HMI | Startup & Commissioning | Project Management

Project Overview

A confidential consumer packaged goods manufacturer needed to convert a 250,000-square-foot brownfield facility, built in the 1950s, for a new manufacturing process. The facility had to support raw material storage, batching, filling, and packaging within the limits of the existing building. The challenges included outdated electrical infrastructure, abandoned building spaces, poor site grading and drainage, and fitting new process equipment into the existing building.

Scope of Work

Matrix Technologies ran the project in three phases (laser scanning, demolition, and engineering) through startup, including:

• 3D laser scanning and modeling of the existing facility to guide demolition and design
• Demolition planning for existing walls, slabs, offices, restrooms, and site features
• Building modifications, including a new 7,000-square-foot area with offices, conference rooms, locker rooms, a cafeteria, a control room and lab, restrooms, and shipping and receiving offices
• Site improvements, including a tanker truck unloading station, grading and stormwater drainage, a retention pond, and a 60-space employee parking lot with lighting, fencing, and secured access
• Process and equipment design, including tank and equipment specifications and procurement support
• Power distribution upgrades, a new electrical room, and facility-wide LED lighting
• Specification and placement of more than 200 instruments
• Control panel design and procurement, ControlLogix and FactoryTalk View SE programming, and pre-shipment testing
• Contractor installation support, startup and commissioning, and project management

Project Results

The aging facility now supports the client's new process from raw material receiving through filling and packaging. New grading and drainage stopped water from pooling in the tanker unloading area. The upgraded power distribution and controls give the process the capacity and automation it needs, and the facility is set up to meet current operations and future growth.