EPIC Systems was awarded the project due to its ability to meet the condensed timeline and its efficient engineering and fabrication techniques. To ensure confidentiality and maintain high construction standards, EPIC built and assembled all modular skids in its advanced fabrication shop. The project engineers and manufacturing crew worked tirelessly, including overtime, to meet the tight schedule. Collaborative efforts between EPIC and the customer during fabrication ensured adjustments were made promptly, and progress was continuously monitored.
Each skid was meticulously designed to fit the small factory footprints and navigate through narrow doorways during installation. Piping organization on the blending skid was simplified for easy maintenance and change-out of raw material connection points. Both skids were delivered pre-wired and ready for utilities hook-up, streamlining the installation process.
The main batch manufacturing process skid was designed to handle raw materials from multiple sources, incorporating valves, pumps, and mixers programmed to follow a precise batch sequence. Additionally, a raw materials pre-mix skid was engineered to provide fragrances and dye to the blending skid, enhancing efficiency in the production process.
EPIC’s scope also included comprehensive calculations for heat tracing, loading, and electrical requirements, ensuring seamless integration of the new systems with existing infrastructure. Integration with packaging equipment was executed to enhance communication and data acquisition, contributing to overall equipment effectiveness (OEE).
A sophisticated batching control system was programmed to meter ingredients accurately based on customer-defined recipes, incorporating fail-safe measures to ensure precise mixing. Furthermore, EPIC installed two flow meters with different measuring technologies to meet the customer’s stringent accuracy requirements.
