Case Study: ProFab Delivers Installation for Large, New Facility

ProFab was selected to support a large-scale equipment installation for a brand-new food processing facility. This was an ambitious, high-stakes project involving hundreds of individual scope items and a complex, evolving install plan. 

From early planning through final execution, the project spanned more than a year and required constant coordination between equipment suppliers, installers, and the client’s internal team. As challenges mounted, ProFab’s experience and leadership became a critical factor in keeping the project moving forward.

THE CHALLENGE: SCALE, COMPLEXITY & CHANGING CONDITIONS

The scope of work was substantial, encompassing more than 300 individual items to install. ProFab was responsible for fabricating and installing extensive conveying systems, platforms, and custom support structures throughout the facility. Each component had to be installed in a precise order based on equipment size, elevation, and limited building access points, leaving little margin for error.

Midway through the project, the complexity increased further when several of the client’s most experienced engineers left the organization. With institutional knowledge suddenly gone, internal planning began to falter. Layouts, sequencing, and logistics decisions stalled, creating a real risk of delays, rework, or idle crews if the installation proceeded without clear direction.

PROFAB STEPS IN TO LEAD

Rather than waiting for direction, ProFab took a proactive role in stabilizing the project. Drawing on its millwright and mechanical contracting experience, the ProFab team revisited existing plans, identified sequencing conflicts, and reorganized the installation strategy to align with real-world constraints.

This included:

• Revising layouts to ensure equipment could be installed in the correct order
• Resequencing installs to account for equipment size and building access limitations
• Coordinating logistics to prevent bottlenecks and downtime
• Making informed decisions on workflow when client-side direction was unavailable

In several instances, ProFab identified sequencing issues that—if left unaddressed—would have completely stalled the installation, requiring major tear-outs or costly rework. By addressing these risks early, ProFab kept progress moving and protected the overall project timeline.

EXECUTING A HIGH-STAKES INSTALLATION

The installation demanded careful coordination across multiple trades and phases. Large conveyors and structural components had to be installed before access was restricted by surrounding equipment. Platforms and support structures required tight tolerances to align with processing equipment supplied by others. Every decision had downstream implications.

ProFab’s ability to see the entire system—not just individual components—allowed the team to execute the work efficiently despite constant change. Our hands-on understanding of how equipment is actually installed and operated proved invaluable in a project where theoretical plans often conflicted with field realities.

A COMMITMENT FEW CONTRACTORS CAN MAKE

Internally, this project also represented a significant commitment for ProFab. Large, long-duration installations require substantial manpower, planning resources, and risk tolerance—factors that prevent many contractors from taking on jobs of this scale. ProFab’s depth of experience, workforce capability, and project management strength enabled us to confidently commit to a project that others would hesitate to accept.

RESULTS & IMPACT

Despite the challenges, ProFab successfully delivered the installation for the new facility. The project moved forward without the major delays that poor sequencing or unclear leadership could have caused, and the facility was equipped with conveying systems and structures that were installed correctly the first time.

Most importantly, ProFab’s involvement helped fill a critical gap when the client needed it most, providing direction, experience, and accountability at a pivotal moment in the project.

A TRUSTED PARTNER FOR COMPLEX INSTALLATIONS

This project underscores what sets ProFab apart. As an experienced millwright and mechanical contractor, ProFab doesn’t just install equipment; we lead complex projects, solve problems in real time, and take ownership when conditions change. If you’re planning a large-scale installation or facing challenges that require experienced hands and decisive leadership, contact ProFab to discuss how we can support your next project.