Solution
The Burns & McDonnell design team was selected by Tyson to create innovative solutions for the facility that would accommodate the growth in production.
After reviewing production data and forecasted growth, our team suggested an expansion that involved a total process floor reconfiguration. The initial design showed a required footprint expansion of 18,000 square feet. Because the physical space for growth was limited, the expansion was accomplished mostly by building processes up instead of just out.
Working with an initial 4,800 square feet of floor space, our team had to install a new process line — a project that involved blenders and stuffers, grinders, ovens, scales, baggers and conveyors. Of special note, a 40-cubic-foot spiral freezer, three refrigeration compressors and multiple evaporators were added. In total, ammonia refrigeration was increased by 300 tons to support the new equipment.
Modifications to the existing building were required to create space for the larger spiral freezer. Adjustments included removing a section of the roof, then building a penthouse to contain the drives and motors that controlled the new equipment.
Our process allowed Tyson to continue operations without disruption. To address the additional refrigeration process load, the design incorporated evaporators that hang from the ceiling and blow onto the floor to maintain the required low temperatures. The engineering team designed specialty stainless steel blast deflectors to redirect cold air flow from the evaporators and away from the mezzanine level where employees would be working, 15 feet above ground. The engineering team also oriented equipment so that it wasn't blowing directly on any of the line workers, maximizing employee comfort.
