Case Study: Overcoming Logistical Challenges During an Install

When a major poultry processor needed new pre-chillers installed in a fully operational facility, the project came with one major challenge: everything had to happen fast and flawlessly. 

The project required careful planning, precise execution, and adaptability to complete during a tightly scheduled production shutdown. ProFab’s mechanical and millwright team took on the challenge, delivering the full scope of work four days ahead of schedule.

The Challenge: Moving Massive Equipment Through Tight Spaces

The facility’s new pre-chiller equipment was massive—each unit roughly ten feet in diameter—and had to be installed at the same elevation as the existing production lines. There was no simple path to get the equipment into the building. To make it happen, ProFab had to open up part of the building itself.

On the first day of the project, the team coordinated a crane, equipment delivery, and the removal of metal wall panels to create a temporary pathway. Existing utilities and equipment were relocated, and even a concrete wall plug was moved and later replaced, all while maintaining the facility’s strict production shutdown schedule.

Every step required careful planning and sequencing. The team had only a few hours during the initial walkthrough to assess the site and anticipate obstacles before quoting the job. Our team’s decades of experience made it possible to quickly identify potential challenges and plan contingencies to avoid delays.

The Solution: Planning, Adaptability, and Deep Field Experience

Once installation began, ProFab’s experience became the defining factor. With millwright, mechanical, and piping expertise on the same team, we had the versatility to handle every aspect of the project, from equipment handling to utility moves to custom platform fabrication.

Midway through the project, the customer requested design changes to the access platforms surrounding the chillers. We quickly re-engineered, redrew, and rebuilt the new platforms without extending the project timeline. The team’s ability to pivot in real time and fabricate in-house modifications ensured the system fit perfectly within the plant’s tight space constraints.

The Outcome: Delivered Four Days Early

Despite the project’s complexity, ProFab completed the nine-day shutdown project in just five days. The successful outcome was a direct result of meticulous planning, seamless coordination, and the team’s ability to make smart, on-the-fly decisions based on years of field experience.

Partner with the Experts for Complex Food Processing Installs

ProFab’s adaptability, along with our planning expertise and hands-on experience, make us a trusted partner for complex food processing facility upgrades. Whether your project involves moving large equipment, coordinating installation around active operations, or handling unexpected design changes, ProFab has the knowledge and capabilities to get it done—on time and on budget. Contact ProFab today to discuss your next installation project.