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Batch Coater Facility Design Using EPC Project Delivery

EPC method brings new equipment online quickly and minimizes risk.
  • Interior rendering showing the base of the batch coater, related equipment, and a fork lift in the foreground - Gannett Fleming.

    A ground-level rendering of the batch coater helps the client envision how the new addition will function.

  • Cut-away view showing the multi-story batch coater equipment and the stairways and platforms surrounding it - Gannett Fleming.

    A system of stairs and platforms provides workers with safe access to all levels of the fluid bed coater.  

  • Interior rendering with translucent walls providing a view into the room that will house the weigh and dispense booth and unloading scales - Gannett Fleming.

    Rendering offers plant operators a look at the new weigh and dispense booth and unloading scale.

  • Three different exterior views from the BIM model showing the planned addition to create a new batch coater facility and warehouse - Gannett Fleming.

    The BIM model provides detailed views of the new batch coater facility and warehouse addition.

Confidential Client

North Carolina

Our Role
Architecture, Mechanical, Electrical, Structural, Plumbing, Civil, Process Engineering, Instrumentation, EPC Project Delivery.

10,000 sq. feet
Construction Cost
$18.6 million
In progress
New Construction
  • New batch coater allows the client to expand production to meet increased demand
  • EPC project delivery saved four to six months versus conventional design-bid-build
  • Project definition package completed in eight weeks to expedite project approvals
  • Guaranteed maximum price and turnkey project reduces the owner’s risk
  • Plan ensures the efficient flow of personnel, materials, and waste products.

In order to meet rising demand, a leading manufacturer of animal food products needed to quickly expand its batch coating capacity at its North Carolina facility. Batch coaters are used to uniformly apply liquid or powder ingredients to a product without damaging it. At this plant, the batch coater sprays and dries a 25 to 35 percent salt solution onto raw granulate. This highly specialized equipment is several stories high and requires a carefully planned facility to properly support it.

The client turned to Gannett Fleming to expedite the addition of a new stand-alone batch coater through our EPC project delivery approach. Our process engineers worked closely with the client’s process experts to integrate the new equipment and warehouse space in a way that would optimize personnel, material, and waste flows. Together with the design team, they explored various options for the addition that would best meet the client’s goals for efficiency and worked within the constraints of the existing site.

What We Did

During the programming effort, architects and engineers developed three potential layouts and then worked with the client to select and refine the best fit. The 10,000-square-foot addition includes a new warehouse to store raw materials prior to coating, a new coater room, and a staging area to hold completed product before it leaves the facility. After the building arrangement was confirmed, designers created floor plans, elevations, and a steel frame concept. 

Our cohesive team managed the process design and building design simultaneously. Engineers developed piping and instrumentation diagrams for each phase of the manufacturing process and planned and sized utilities to support demands. We prepared detailed cost estimates with input from subcontractors, and led value engineering efforts that reduced overall project costs. Within eight weeks, the team delivered a project definition package with a guaranteed maximum price that allowed the client to start the project quickly, with a high degree of confidence and minimal risk.

Key Features

  • A coordinated process allowed site work to proceed while the building’s design was finalized
  • The addition is designed to minimize the building’s footprint and allow for future expansion
  • To expedite the project, the addition will be constructed and the new batch coater will be craned into place upon arrival
  • Proper pressurization of spaces minimizes the risk of cross-contamination
  • Galvanized frame platforms and stairways provide safe access to the batch coater’s multiple levels.

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