Neat Soap System

Client: Confidential
Location: Midwest U.S.

Summary

Burns & McDonnell designed, commissioned and started up a soap system for a major consumer goods client in its Midwest plant. The design was based on the latest soap-making technology offered by Italy’s Mazzoni LB. The system, installed on a new three-level platform structure, produced up to 11,000 pounds per hour of neat soap, a key ingredient of the bar soap manufactured at this plant. The project also reconfigured and expanded the plant’s raw material storage capacity to accommodate different materials required by the new system.

A full array of engineering disciplines performed preliminary and detailed design for this project, including process-mechanical, civil, structural, electrical, instrumentation and architectural. Burns & McDonnell provided construction supervision, acting as the owner’s engineer.

Burns & McDonnell developed a thorough commissioning plan and led a five-week-long commissioning and startup effort. We worked closely with the owner’s process engineers, crafts and on-site controls integrator. The startup was vertical, and the system was successfully turned over to operations without any safety incidents.

Value Engineering

The project team conducted several value engineering workshops before making key design decisions. The team brainstormed the pros and cons of all competing alternatives using a rating matrix with criteria such as installation cost, operational and logistical complexity, life cycle operating cost, safety, quality and flexibility. Creative design maximized decommissioning of existing capital assets, thus minimizing new capital spend. Value engineering produced more than $1 million in savings.

Services

  • Preliminary engineering
  • Value engineering
  • Detail engineering
  • Project management
  • Commissioning
  • Startup

Background

A full array of engineering disciplines were required to perform preliminary and detail design for this project including process-mechanical, civil, structural, electrical and instrumentation, as well as architectural. During construction, Burns & McDonnell provided construction supervision acting as the owner's engineer.

Burns & McDonnell developed a thorough commissioning plan and led a five-week-long commissioning and startup effort. We worked closely with the client's process engineers, crafts and on-site controls integrator. The startup was vertical and the system was successfully turned over to operations without any safety incidents.

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