Front-End Loaded (FEL) Pre-Engineering Services Identifies APC Challenges
IR Process is a Design-Supply-Build process engineering company with Subject Matter Expertise (SME) regarding material handling & processing applications. One of the services IR Process provides for our customers is pre-engineering services, also known as Front-End Loaded (FEL) engineering services. Why are FEL engineering services important for many process improvements that a facility is considering? The answer is simply because FEL engineering services should provide an industrial facility with more accurate costs and potential risks associated with process improvements and expansions the facility would like to consider for a minimal investment.
Customer Request
IR Process received a request from a large, international food producer to assist with design & supply of a recycling system for animal by-products (ABP). The customer had initiated some preliminary process evaluations and had even completed product testing with a few of the equipment manufacturers they felt would be required for the primary equipment components. The preliminary equipment included.
- Drying systems
- Size reduction
- Air classification
During our kickoff meeting, the customer shared preliminary budgeting they had developed and based on our experience, our team had concerns the project was significantly underestimated but wanted to do our due diligence prior to sharing our thoughts with the customer. IR Process recommended that a FEL be completed to be sure all design parameters had been accounted for prior to initiating final design services and equipment purchases.
As a standard, IR Process approaches FEL engineering services from the 50,000-foot level to ensure all options are considered before narrowing down to specific equipment. In addition, we consider water, wastewater, power, emissions and other utility and environmental conditions created during the process. The customer had a team made up primarily of maintenance & operations personnel along with recent engineering graduates.
IR Process zeroed in on the air flows and emissions that would be required for the drying, sizing and air classification equipment and if these emissions would require pollution mitigation systems. Most ABP products will give off emissions that require pathogen control, odor control & particulate control – among other possible treatments. Preliminary estimates to treat the air flows would require equipment that was 200% the cost of the process equipment
At that point, we contacted our customer to explain our findings and asked if they would like to proceed with the detailed engineering. The customer requested that we not complete the full scope of the FEL because the cost point was not acceptable for management. IR Process allowed the customer to cancel the remainder of the contract to complete the FEL and most of the budget was not used.
Applying a System-Specific Approach to Every Project
This project is one example of how IR Process partners with customers to evaluate their plans for change. Whether it’s a new process or retrofit of an existing process, completion of a FEL should be completed before major capital decisions are made. By taking a system-specific approach, our process engineers help clients reduce risk, clarify scope, and sequence projects effectively. Contact our engineers to discuss your application or request a quote to begin defining the right path forward.