Case Study: How ProFab Rescued an Installation Gone Wrong

Industrial installation projects rarely go exactly as planned, but when multiple contractors, inaccurate drawings, and pandemic-related labor shortages collide, even experienced facilities can find themselves in trouble. That was the situation facing a food processing facility in Camilla, Georgia, during the height of COVID-19. A competitor-led installation effort had stalled, errors had compounded across trades, and the project timeline was at risk.

With limited internal resources and growing operational pressure, the facility needed a partner who could step in midstream, quickly assess the damage, and take ownership of completing the job correctly. That’s when ProFab was called in.

THE CHALLENGE: A PROJECT IN DISTRESS

By the time ProFab arrived on site, the project was already facing multiple critical issues. Several contractors had contributed to the work, but coordination gaps and installation errors had left the facility with incomplete and improperly installed systems.

Two major problems stood out immediately. The shackle line (overhead conveyor) had been mislocated and was not properly installed, and the trench drain had been installed incorrectly. At the root of these issues was a common—but costly—mistake: the original contractor relied on drawings without fully verifying actual site conditions. The as-built environment did not match what was on paper, and no adjustments had been made to account for the discrepancies.

Adding to the complexity, COVID-19 had significantly reduced available labor. Facility personnel were unavailable due to illness, leaving ProFab to take on the work with our own crew under tight constraints.

PROFAB STEPS IN

ProFab approached the project with a field-first mindset. Rather than assuming existing plans were correct, our team conducted a thorough on-site evaluation to understand what was truly present and what needed to be corrected. This practical, experience-driven approach allowed ProFab to identify misalignments quickly and develop a clear path forward.

Despite the high-pressure environment and the risk associated with taking over a troubled project, ProFab committed to seeing it through. With no on-site support from the customer, our team assumed full responsibility for execution.

THE SOLUTION: REMOVE, REBUILD, REINSTALL

The improperly installed shackle line had to be removed entirely. ProFab dismantled the overhead conveyor, rebuilt components as needed, and reinstalled the system in the correct location to ensure proper operation and alignment. Simultaneously, the team corrected the trench drain installation, resolving a critical sanitation and functionality issue.

While much of the equipment was supplied by other manufacturers, ProFab’s value came from expert installation and coordination. The team rearranged equipment layouts, adapted to real-world conditions, and ensured all systems were installed correctly—this time based on what was actually on the floor, not just what was shown in the drawings.

THE RESULT: A PROJECT BACK ON TRACK

Despite inheriting a project riddled with errors and working through the challenges of the COVID-19 pandemic, ProFab successfully completed the installation using our own skilled crew. The facility was able to move forward with confidence, knowing the systems had been properly installed and aligned for long-term performance.

This project stands as a clear example of ProFab’s enduring commitment. When others fall short, ProFab doesn’t walk away—we problem-solve, adapt, and finish the job.

PROVEN EXPERIENCE WHEN IT COUNTS

As an experienced millwright and mechanical contractor, ProFab is trusted to step in when projects go off track and to deliver results when the pressure is highest. Whether rescuing a failed installation or executing a complex project from the ground up, ProFab brings the field expertise, adaptability, and determination needed to get the job done right.

Need a partner who won’t give up when the project gets complicated?

Contact ProFab to discuss your next installation and learn how our team can help ensure success from start to finish.