Confidential Client
Midwest USA
Paints & Coatings
Overview
A leading manufacturer in the paint and coating manufacturing industry experienced significant growth driven by increasing demand across consumer and industrial markets. To meet production requirements and position the facility for continued expansion, the company launched a capacity increase initiative at an existing manufacturing site.
The project centered on integrating new production equipment into an active operating facility while maximizing the value of existing assets and minimizing disruption to ongoing operations. Nexus Engineering Group was engaged to provide the engineering and design services necessary to successfully incorporate new paint mixers and supporting infrastructure into the existing manufacturing process.
The primary objective was to increase production capacity by incorporating new mixing equipment, improving process efficiency, and optimizing available plant space. The scope included manufacturing equipment design, structural modifications, piping and utility integration, instrumentation and controls, and coordination of equipment installation activities required to support the facility expansion.
Challenge
The project presented several unique challenges associated with retrofitting new equipment into an existing manufacturing environment.
Unlike greenfield facilities designed around specific process equipment, the client's approach involved purchasing production equipment in advance and then adapting the facility and process systems to accommodate it. This required extensive evaluation of existing conditions and careful coordination to ensure the new equipment could be successfully integrated without negatively impacting ongoing production activities.
One of the most significant challenges involved accommodating new vertical paint mixer machine technology within a facility that had historically relied on horizontal mixing systems. The new equipment featured a substantially different footprint, elevation profile, and operational layout than the existing mixers. To maintain production flexibility, the client wanted to preserve existing equipment while also integrating the new systems, creating additional complexity around equipment placement, structural requirements, and process routing.
Space constraints within the operating facility further complicated the design effort. Existing structures, utilities, and process systems limited available installation space and required detailed coordination to identify a workable solution. Modifications to surrounding equipment and support structures were necessary to ensure safe operation, maintenance accessibility, and compliance with facility requirements.
The project team also faced equipment delivery delays and late-stage vendor specification changes stemming from broader supply chain challenges. When equipment arrived onsite, deviations from original vendor data required engineering revisions and rapid coordination between multiple disciplines to maintain project momentum and support the installation schedule.
Solution
Nexus developed a comprehensive engineering solution that enabled the client to successfully integrate new manufacturing equipment while maximizing the efficiency of the existing facility.
Working closely with plant stakeholders, Nexus evaluated available space, process requirements, and structural constraints to develop a retrofit strategy that accommodated the new vertical mixer systems while maintaining operation of existing equipment. The team designed modifications to the mezzanine and supporting structures to provide sufficient clearance, accessibility, and operational support for the new equipment configuration.
Through detailed coordination across mechanical, structural, piping, electrical, and controls disciplines, Nexus created an integrated design that streamlined installation and minimized disruption to plant operations. The solution allowed the client to leverage the smaller footprint of the vertical mixer technology while preserving existing production assets and infrastructure.
Nexus also provided rapid engineering support throughout equipment procurement and installation, addressing specification changes and field conditions as they arose. This proactive approach helped mitigate schedule impacts, resolve vendor-related issues, and maintain project progress despite evolving project requirements.
The completed expansion increased production capacity, improved operational flexibility, and enhanced overall manufacturing efficiency. By combining practical engineering solutions with a collaborative project delivery approach, Nexus helped position the facility for continued growth while supporting the client's long-term production objectives in the competitive paint and coating manufacturing market.
Services
- Manufacturing equipment design
- Machine retrofitting and equipment integration
- Process engineering support
- P&ID development
- Equipment sizing and specification review
- Line sizing and hydraulic calculations
- Structural steel design and detailing
- Mezzanine modification design
- Piping and pipe support design
- Instrumentation and control system design
- Control panel design
- Electrical power and control systems
- Wiring diagrams
- Construction and installation support
Project Director
