Complex Packaging Line Relocation & Upgrade

A well-known food manufacturer hired SSOE to design, install, and start-up the process and packaging lines for their newly upgraded facility in North Carolina to allow the production of its new brand. To accommodate an aggressive schedule, the team held an interactive planning (IAP) session at 60% design development to consider alternative methods to ensure successful delivery of this complex project—ultimately enlisting the help of SSOE Systems, our construction management division.

By using a criteria package instead of a more traditional bid document, we were able to start installation before design was completed, resulting in significant time savings. The team only had a small window of time to move the equipment and get the repurposed facility up and running. One team member provided on-site assistance at our client’s west coast facility where the equipment was removed and another in the facility in North Carolina where a combination of both repurposed and new process and packaging equipment was being installed. Moving into the installation phase the team realized many of the 2D installation drawings were incomplete and quickly decided to use the 3D model as the construction guide for installation. This minimized rework and ensured the team was working from the most current design, providing the ability to confirm dimensions in real time as equipment was being installed and maintain a high level of activity at each site to achieve our client’s tight timeframe.

On-site in North Carolina, we held daily reviews around the model with the contractors. With more than 30 different systems interacting together, a visual tool became necessary to keep the trades moving. Contractors were able to show 3D renderings to the trades below them to provide a better idea of how everything would go together. There were a couple of very specific cases with pipes at two to three different angles, making it difficult for contractors to lay out at ground level. We were able to measure spool pieces, or certain sections of the pipe, directly through the model, and the contractor fabricated to our dimensions seamlessly, which was especially beneficial on the more complicated runs.

Late in construction, a permitting issue was discovered for the process equipment. We negotiated with the county, who ultimately agreed to us running the equipment while documentation was being created for the permit as we were nearing the checkout phase of the project—and allowed equipment training without an occupancy permit.