Menu
Menu
Menu
One message that has resounded over the last few years is that everything changes – and production environments are no different. In a world where “change is the only constant,” how do teams – or rather, how should teams – approach enhancing or scaling their manufacturing processes? Skid-based systems are one such solution that are highly sought after due to their modular nature. Their scalability, versatility, and cost-effectiveness have made them attractive solutions across nearly every industry – from food to pharma to chemical to industrial products. For decades, Re:Build Optimation has helped customers design, build, and deploy custom skid-based systems and modular workstations that not only solve the customer’s process challenges but provide a long-term cost-benefit as well.
This blog is the first in a series on the advantages of skid-based systems and modular design in manufacturing. Here, we’ll look at what modular thinking is and explore different types of system designs through real-world examples.
Modular thinking involves taking a complex system and breaking it down into unit operations. In manufacturing, this could be assessing an end-to-end production line, identifying all the process steps, and determining where those steps can be separated into discrete functions. Problem solving using this approach typically leads to better long-term solutions, as customers often require systems that can be easily modified, expanded, or replicated to accommodate business growth. This flexibility is crucial for adapting to changing market demands and scaling operations effectively, and in environments that demand both efficiency and quality, it’s a game-changer when you can add new components or replicate existing ones with minimal disruption and cost.
A practical example of modular thinking is in the design of chemical plant utility systems. A chemical plant’s boilers are comprised of many systems that work together, one of which is the condensate return system. This system includes a tank, pumps, instrumentation, and a control panel, and its purpose is to save energy by collecting condensate from different parts of the system and returning it to the boiler. To determine how this process could be modularized, Re:Build Optimation first considers the process holistically and then breaks it down by function, assessing how the process can be optimized for rate, quality, and equipment footprint. For this system, the entire process can be mounted on a skid designed to autonomously perform the specific process tasks without the need for operator oversight. This solution illustrates how modular components can be integrated and unitized to support larger, more complex processes.
The concept of modular thinking is fundamental in the design and implementation of skid-based systems and process solutions. When considering a modular process solution, there are a couple different types of systems that are important to know (among others): process skids and modular workstations. While there is some overlap in the definition of these two tools, there is an important distinction. A workstation typically implies that there is some operator participation involved, while a skid, being all contained, has a level of automation that does not necessarily require the involvement of an operator.
Taking this idea a bit further, workstations tend to be machines designed to add value to something being manufactured or produced. For example, they might be assembly stations or inspection stations, each having operators performing part of the “work” that is being done. Skids tend to be complete process units, often associated with continuous processes involving liquids, solids, or gases – like in a water purification system or filtration skid. When the process components cannot be confined to a single skid for reasons like size or complexity, Re:Build Optimation suggests a system composed of multiple interconnected units, which could include large tanks, compressors, or gas mixers, that are assembled as a modular workstation.
Adjacent to skids and modular workstations, Re:Build Optimation has also done a number of test stands and Clean-In-Place (CIP) systems, the latter being a critical application of modular thinking in food, pharma, and medical devices. CIP systems are specialized modules designed to thoroughly clean and sanitize production equipment and piping, and use a combination of chemical agents, flushing, and testing to ensure all traces of previous substances are removed, preventing cross-contamination. This process is essential for maintaining high standards of cleanliness and complying with regulations such as Good Manufacturing Practices (GMP). Companies like Carestream, Kodak, Ortho Clinical Diagnostics, and Thermo Fisher have all utilized CIP systems to maintain the cleanliness of their equipment. For instance, in Kodak’s emulsion process, any residual dye left in the system from a previous run could ruin subsequent batches, leading to significant financial losses. Their process requires multiple cleans between dye runs to prevent contamination, and a CIP system ensures that the equipment is thoroughly cleaned and ready for the next production cycle every time, emphasizing the importance of cleanliness in maintaining product quality.
Determining whether a modular system will work for you and then narrowing down what system design (e.g., a skid or workstation) can be a frustrating experience, especially for those who do not have much experience in this area. If you are looking for improved operations flexibility, speed, and reproducibility, then a modular option might be the right choice. At Re:Build Optimation, we prioritize understanding the problem you are solving and then exploring all available technologies, often employing modular thinking, to identify the solution that provides the best value for the customer; we believe that there is no “one size fits all” solution, even for companies within the same niche market segments. When customers come to us looking for a solution to their process challenges, we find they typically fall into one of two categories:
The latter is more common, where clients seek assistance in transforming a lab-scale or conceptual process into a viable commercial system. This involves significant engineering effort to determine the optimal form factor and process delivery method. Regardless of which category you may align with more, or if you’re simply curious about skid-based systems and modular production methods, Re:Build Optimation can help you find the right solution.
Modular systems offer innovative solutions for process challenges in manufacturing across any industry. Skid-based systems and modular workstations provide unique, process-specific solutions that are tailored to the diverse environments in which they’re deployed. They enhance efficiency, reduce downtime, ensure compliance with rigorous standards, and are designed for mobility and efficiency, making them ideal for addressing production expansions or capacity issues. By leveraging modular thinking, Re:Build Optimation helps customers achieve greater flexibility and adaptability in their manufacturing processes, ultimately leading to higher productivity and product quality.
Coming up, we’ll dive deeper into the advantages of skid-based systems in the modern production environment, and later discuss what design considerations are important when building modular systems for diverse environments.
Looking to connect with an experienced team?
Look no further than Re:Build Optimation! We are excited to connect with you.
