How to Go Fast and Still Manage Risk
In manufacturing, speed is often positioned as a critical competitive advantage. The quicker you can launch a new production line, scale up capacity, or bring a system online, the sooner you can meet customer demand, improve margins, and capture market share. But speed that compromises safety, quality, or regulatory compliance is not a smart tradeoff. It introduces risk that can derail an entire operation.
Automated Robotic System for Solid Oxide Fuel Cell Stacking
A manufacturer in the energy sector set out to transform one of its facilities from a research and development site into a scaled production environment for Solid Oxide Fuel Cells (SOFCs). To support this transition, the company needed to replace a limited in-house system with a fully automated, high-throughput machine capable of assembling SOFC stacks with speed and precision.
Determining Hazardous Area Classification Early
When companies scale from a benchtop lab to pilot-scale production, many focus on process efficiency, space requirements, and throughput. But too few stop to ask one essential question: Are we operating in an electrically hazardous environment? At Re:Build Optimation, we’ve seen how early hazardous area classification (HAC) assessments can fundamentally change the trajectory of a manufacturing project. When addressed early, HAC acts as a hidden risk reducer, informing design decisions, avoiding costly rework, and ensuring safety and compliance from the start. This blog breaks down why early HAC matters and how to approach it as a strategic investment rather than a compliance chore.
Start with AHJ Engagement
For startups working in specialty chemicals, advanced materials, or energy storage, the transition from lab to pilot plant presents many challenges. Among the most underestimated is regulatory compliance. At Re:Build Optimation, we have seen how early engagement with the Authority Having Jurisdiction (AHJ) often determines whether a project progresses smoothly or faces costly delays. This blog draws on real-world engineering experience and outlines a practical approach to the occupancy permitting process. Startups that take a proactive approach not only avoid rework and reclassification issues, but also gain credibility with regulators, community stakeholders, and potential investors.
Tramming Rods
High-quality, custom engineered and manufactured systems for hydrogen generation, fuel cells, electrolyzers, reformers, end of line test, and dispensing.
Web Handling White Papers
Web Handling White Papers Air Conveyance The Fluid-Structure Interaction in Supporting a Thin Flexible Cylindrical Web With An Air Cushion This white paper presents a theoretical and experimental investigation into the dynamic behavior of thin web materials, such as plastic films or paper, as they interact with surrounding airflow during high-speed transport. The study focuses on […]
White Paper: Chemical Manufacturing Scale-Up
WHITE PAPER Safe Scaling: A Process Safety Playbook for Chemical Manufacturers Scaling up in chemical manufacturing isn’t just about boosting output, it’s a high-stakes transition that introduces new equipment, materials, and hazards. This in-depth white paper offers a practical guide for integrating Process Safety Management (PSM) into scale-up projects to protect people, processes, and profitability. […]
Process Scale-Up Prioritizes Reliability, Not Perfection
When chemical manufacturers begin planning a process scale-up, they often bring with them a mindset rooted in optimization. What is the most efficient reaction time? The ideal flow rate? The perfect temperature? These are valuable questions in the lab, where experimentation is safe and manageable. However, as you move from bench-scale experiments to commercial production, the focus must shift.
Why Safety Is a Smart Growth Strategy for Chemical Manufacturers
As specialty chemical manufacturers scale operations to meet rising demand, introduce new products, or expand into new markets, they often face a hidden challenge that can derail growth entirely: process safety. Scaling is not just about producing more. It introduces new materials, more complex systems, and greater operational risks. While increasing capacity is a business goal, managing safety is a business imperative. That is where Process Safety Management (PSM) becomes essential.
White Paper: Mitigating Risk in Hydrogen Manufacturing
WHITE PAPER Mitigating Risk in Hydrogen Manufacturing Hydrogen manufacturing is fueling the clean energy transition, but not without risk. As demand for hydrogen grows, so do the safety, environmental, financial, and operational challenges that come with producing, storing, and distributing this volatile energy source. This white paper explores the hidden risks of hydrogen manufacturing and […]