EPIC Systems engineered, fabricated, and installed an integrated large-scale process system with a complete packaging line. This included raw material tanks, piping, an automated batch mixing system, a high-speed rotary filler, unscrambler, labeler, and case packer.
At the core of the process system was a complex, multi-stage automated batch mixing system that ensured product consistency and repeatability for the liquid cleaning product. To support this, EPIC implemented raw material storage and transfer systems capable of handling both liquid and powder ingredients, including an automated tote and drum retrieval system to feed the batching process efficiently. The entire process was managed by an advanced control system, rigorously simulated and tested prior to startup.
Key execution strategies to meet the project’s challenges included:
- Smart project management: EPIC assigned separate project managers for the process line, packaging line, and on-site construction, allowing specialized oversight while maintaining a lean staffing model to keep projects moving.
- Parallel build strategy: Process systems and packaging lines were assembled and installed simultaneously but treated as separate systems until each completed full startup, avoiding schedule roadblocks.
- Shift-based trades: By staggering mechanical and electrical contractors into separate shifts, EPIC eliminated workspace conflicts and maintained construction momentum.
- Pipe-first strategy: All PVC piping was installed prior to receiving valves and instruments, which were then integrated upon arrival by cutting into the existing piping. This eliminated valve and instrument lead-time delays.
- Extensive controls testing: The complex PLC and HMI systems were tested with simulation software before any chemicals were introduced. This included fail-mode scenarios to validate automated responses and avoid costly product losses.
- Data-centric monitoring: Flow meters and weigh cells with alarms continuously monitored the batching process, providing actionable data to operators to prevent off-spec product or system failures.
The first product batch produced through the new batch mixing system was immediately sellable, with no additional scrap costs incurred during startup thanks to extensive pre-startup controls testing. Following the successful launch, the client partnered with EPIC to expand the system further, adding new ingredients, recipes, and additional engineering and automation improvements.
