Advantages of skid-based systems in the modern production environment

Why Skid-Based Systems?

There is typically more than one viable solution to a particular problem, so how do you know which solution is the best? By identifying and prioritizing the operating parameters that are present in your system and doing a cost-benefit analysis for each option, you can select the one that best meets your needs. Skid-based systems are often ideal solutions for several reasons, offering benefits like:

• Improved capacity and scalability
• Versatile system deployment
• Enhanced safety and efficiency
• Process verification and quality control

While these advantages are great individually, the real power behind modular design lies in achieving all of them with one system. Let’s take a closer look at how skid-based systems enable companies to advance and improve their manufacturing capabilities.

Improved Capacity and Scalability

The modular design of skid-based systems simplifies installation and operation, creating a “plug-and-play” solution that can be quickly connected to existing infrastructure with minimal disruption. This flexibility enables customers to easily scale their operations by providing a mechanism through which discrete processes can be unitized. Additionally, skid-based solutions can be designed specifically for the environment in which they will be deployed, optimizing production space and capacity. You may be wondering, “what happens if my production floor plan changes after the new system has been installed?” It’s a great question, and one that skid-based systems are uniquely positioned to address. The inherent modularity means that customers can easily adapt to evolving business needs and scaling demands. For instance, a pressure test system might initially be installed with four bays, with the intention of adding a fifth at some point in the future. The later addition of the fifth bay is possible because the initial system was designed to have pre-installed supply and return pipes, enabling easy system expansion. This plug-and-play approach minimizes production disruptions and allows for efficient scalability when needed.

To see this advantage in action, let’s look at the work Re:Build Optimation did for Byogy Renewables, Inc., an American biofuel organization. The 2020 Summer Olympics were to be held in Japan with a primary theme of sustainability. Housing, medals, uniforms, etc., were going to be made from recycled materials, and it was desired that the jets used for the stadium flyover would use fuel made from farm waste. Byogy already knew the chemical processes required to convert any form of ethanol or butanol into low carbon renewable fuels, but didn’t know how to design and build a system that would perform this process at scale. Re:Build Optimation identified this as an opportunity for a skid-based system because of the desire to scale while still meeting strict safety standards in a high-pressure environment. The success of this pilot project was made possible through modular design and validated that a global alternative fuel specification could be commercialized. This empowers Byogy to expand commercialization of its proven technology as it continues to push for fully synthetic fuel use in the future.

Versatile Deployment

Another advantage of skid-based systems is their versatility, whether that be in form factor or the environment in which they are deployed. Skid-based systems can come in many form factors, such as benchtops, backplates/wall mounts, cart-based portables, standard and custom shipping containers, trailer-mounted units, and custom-built frames, providing a wide range of options to suit specific needs. These containers are ideal for housing equipment that needs to be protected from external elements while maintaining mobility. The versatility of these systems is evident in their ability to support internal processes or to operate independently in remote locations.
Skid-based systems provide mobile, nimble solutions that are adaptable to different environments. For example, a major supplier to the oil and gas industry doing work in the Pacific Rim needed infrastructure to support their exploration and testing in that area. This required the high-pressure test stands to be designed and fabricated prior to shipping half-way across the globe, with the software being run from Re:Build Optimation’s facility in Rochester, New York. A skid-based system allowed for the entire test stand to be constructed within a container that was easy to transport to and install at the customer’s site – once it arrived, all the customer had to do was run piping in and then they were ready to go. This solution proved to be more robust than what competitors were offering due to its optimized form factor and unitization.

Enhanced Safety and Efficiency

Safety is another critical advantage of modular skid systems. Constructing these systems in a controlled environment allows for stringent safety protocols to be followed and for better management of potential hazards. Once the system is built and tested in-house, it can be transported and installed on-site with reduced risk to the customer.
In comparison to traditional on-site construction, skid-based systems offer a faster installation process because they can be built off-site, allowing for parallel path activities that reduces the time required for installation and minimizes production downtime. For example, the installation of a typical skid-based system might take two weeks, whereas constructing the same system on-site could take anywhere from 10 to 20 weeks while significantly impacting production.
In the glass and ceramics industries, companies like Owens Corning illustrate the benefits of modularity as they plan maintenance and upgrades years in advance to minimize downtime. This emphasizes the need for systems that can be quickly replaced or upgraded without lengthy outages, and modular systems offer a desirable solution that is designed specifically for their application. Similar principles apply to other industries, such as oil, gas, and chemicals, where modular systems reduce lost revenue during maintenance and upgrades by minimizing downtime.

Process Verification and Quality Control

Additionally, skid-based systems enable thorough testing and quality control prior to installation, and are ideal for implementing process improvements and verifying new manufacturing techniques. Every system is subject to Factory Acceptance Testing (FAT) that is conducted at the manufacturing facility with client participation, ensuring the system works as intended. By performing this testing first at the manufacturing facility, Re:Build Optimation has access to all the skills and tools needed to fix anything that isn’t functioning properly, reducing risk and enhancing system quality. Upon acceptance, the system is shipped and re-tested on-site, addressing any minor issues that might have arisen during transport. This two-step testing process ensures that major problems are identified and resolved early, leaving only minor adjustments to be made during on-site commissioning.

Conclusion

Skid-based systems decompose processes into modular components, offering scalable and adaptable solutions for nearly any industry. If you are looking to increase your production capacity, scale your processes, or improve efficiency, quality, or safety, a modular solution could be an ideal choice. Additionally, the flexible nature of skid-based systems means that you have a solution that can be adapted to changing business requirements and environments. For more examples of how skid-based systems have solved real customer problems, check out these case studies.