Case Studies

A renewable energy technology company partnered with Re:Build Optimation to develop a modular methane-to-methanol processing system capable of converting waste gases into valuable chemical products. Designed as a trailer-mounted chemical plant, the system integrated membrane separation, compression, and methanol production technologies within a highly constrained footprint. Re:Build optimized hydrogen concentration,

A renewable energy technology company sought to modernize an existing biomass pyrolysis skid system that had originally been designed and constructed in Europe as a prototype-style machine. The existing unit relied heavily on European-standard components and lightweight extruded aluminum construction that limited durability and industrial scalability.

A developer of next-generation rechargeable energy storage technology sought to scale its laboratory powder production process into a pilot manufacturing operation capable of supporting future commercial battery production.

A manufacturing client relied on an existing production test stand that had originally been developed as a prototype system but was later forced into full-scale production use. Over time, the limitations of the prototype design created operational inefficiencies, excessive operator involvement, and increased opportunities for testing errors and production delays.

A client required a custom precision coating system to support laboratory-scale developmental work involving a wide range of coating materials and process conditions. The system needed to integrate a slot die provided by a third party while delivering highly accurate coating performance across a stationary substrate measuring 16 inches wide

A food manufacturing client required significant modifications to an existing production line to meet updated customer packaging requirements. The facility needed to integrate a new shrink wrapping operation capable of handling a family of products with varying dimensions, packaging configurations, and throughput requirements.

A legacy glass manufacturing plant faced chronic material loss, unplanned downtime, and rising maintenance costs due to aging batch house equipment operating well beyond its intended service life. Re:Build Optimation partnered with the plant team to assess the full batch operation and execute a phased modernization program aligned with production

A glass manufacturer faced increasing material waste and unplanned downtime due to excessive wear and calibration drift in a critical batch house check scale system operating in an abrasive environment. Re:Build Optimation redesigned and modernized the system with more durable materials and upgraded load cell technology to improve accuracy and

A glass manufacturer needed to add green glass production at an existing plant on a fixed timeline to support a product launch, but faced capital and schedule constraints and cross-contamination risks with its existing colorant systems. Re:Build Optimation repurposed and re-engineered a decommissioned colorant premix system, integrating it into the

Glass manufacturers often lack clear, data-backed insight into batch house condition, capacity, and maintenance risk, making it difficult to prioritize capital spending and secure funding for critical upgrades. Re:Build Optimation’s Batch House Audit Program combines on-site engineering evaluation with quantitative capacity and reliability analysis to create a clear, defensible roadmap

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

The manufacturing operation was experiencing wound roll quality issues on film/film laminated products slit and rewound on a REM slitter/rewinder. The problem was described as rolls blowing out and is mostly an issue after winding although there have been problems on 3000 foot 5 to 6 inch wide slits during

Donaldson Company Inc. provides industrial filtration solutions to a variety of markets. To quantify the performance of the company’s filters, they are tested to the American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) specifications to determine how efficient the filter is at removing particles of various sizes. To

Re:Build Optimation modernized a legacy 750-gallon glass-lined reactor by replacing obsolete 1970s-era pneumatic controls and aging piping with a fully updated electronic control and instrumentation system. The project improved safety, maintainability, and regulatory compliance while bringing the reactor in line with current Synthetic Chemicals Division standards and NYS MON/MACT requirements.

A battery manufacturer wanted to increase productivity and total product throughput on a 24-hour cycle using robot technology and other automated peripheral devices.

New College Institute wanted to train the local workforce in Martinsville, VA. The local economy was primarily textile and furniture manufacturing related, with limited technical positions. Two local film manufacturers, Commonwealth and CP Films, were struggling to have enough qualified resources for their facilities. New College Institute approached Ralph Schultz

American Aerogel, a company developing and manufacturing proprietary aerogel insulation products, had been growing rapidly and needed to expand its production capabilities.

Because demand for its product was so high, American Aerogel’s 24/7 operation required new equipment with process improvements to increase production and improve efficiencies.

Because American Aerogel’s products

Greenlight’s Pilot Plant Expansion brought a previously installed fermenter and reactor capacity online with supporting downstream processing capabilities, product formulation, and a product packaging line to support precommercial and commercial product volumes of our first-to-the-world RNA based solutions.

A metal parts manufacturing company required an automatic washing machine that would cut down on manual operation and improve its bottom line. Re:Build Optimation used its material handling and automation expertise to design a machine that would queue, load, unload and sort parts as one automated process. Re:Build Optimation then

A metal parts manufacturing company required an automatic washing machine that would cut down on manual operation and improve its bottom line. Re:Build Optimation used its material handling and automation expertise to design a machine that would queue, load, unload and sort parts as one automated process. Re:Build Optimation then

Grober Nutrition is in the dairy industry for animal food products in facilities built to human food standards, which is unique to the Northeast. Grober’s product is a powdered formula that is used as a milk replacer for young animals. Surplus Whey from a Skim Milk manufacturer is readily available

In early 2020, as part of Project Warp Speed, The Department of Defense funded several pharmaceutical companies to develop a vaccine for COVID-19. This was well publicized. On a parallel path, but not as well publicized, was a program to manufacture vaccine delivery systems. One of two companies funded by

Extreme pressure under the earth affects drilling tools and electronics, so manufacturers of drilling equipment need to test these effects prior to their use in the field to prevent costly accidents. To verify, it is helpful to simulate deep well conditions and subject new tool designs to pressure levels found

McGard, a manufacturer of lugs and locks for the automotive, marine and municipal security industries, purchased a heat treat system from another manufacturing company and needed to install the system at its Orchard Park, NY location. McGard had all of the components and some photos from the previous location, however

Fuel cells have been around for nearly 200 years, and used commercially for nearly a century. With the growing awareness of the need for more environmentally and energy-efficient power sources, fuel cells are gaining promise as clean energy alternatives in various applications, ranging from transportation and material handling to critical

Problems in a film canister cooling water distribution network in the production plant at Eastman Kodak in Rochester, NY were resulting in capacity reductions. Inefficient cooling of product in the molding machines caused adhesion / release problems between the product and the molding equipment. Planned capital improvement options being investigated

A local utility company in Rochester, N.Y. is investing millions to increase Eastman Business Park’s energy efficiency and utilities productivity in order to help attract new businesses and jobs to the region while ensuring compliance with Boiler MACT and other pending environmental regulations. The utility company purchased the Park from

A client in the automotive industry had existing equipment for performing torsion tests on its drive shaft components. The client had an urgent need for a software application to perform the tests and generate data in time for a trade show presentation. Re:Build Optimation had the ability to come in

An undersea cable company was looking for a firm to design and build a high-pressure mixed gas system to pressure test the various undersea components they manufacture. These components are installed into high-pressure vessels and externally gas-pressurized to 2 main pressure setpoints – 15,000 psig or 5,000 psig, and these

Fuel cells are a new clean energy technology that can be used in a wide range of applications, including transportation, material handling, and emergency backup power generation. Many industries today are relying on vehicles powered by Fuel Cell Engines, where hydrogen is used to generate power by a chemical reaction,

A client manufacturing consumer products contacted Re:Build Optimation for web handling consulting. The client’s operation was experiencing significant quality issues and waste generation which was a threat to their production feasibility. The problem was described as the inability of their current equipment to convey sensitive web without inducing roller contact

Synergy is a leading manufacturer and supplier of flavors, extracts, and essences for the food and beverage industries.

Synergy was in the process of relocating its manufacturing from an existing facility in Wauconda Illinois to a new and larger facility to accommodate growth. As part of this process, Re:Build Optimation

A manufacturer of nanomaterials for composites had a product that needed to be produced without being touched or disturbed. The company’s product is manufactured continuously on a roll-to-roll web. The end result is a coated wound roll of a delicate powder, which if touched would abrade off and release into

Fuel cells are a fast-growing market, and that means there can be quality issues with incoming material, especially with the supply chain disruptions that have been experienced in the last couple years. For one client, using catalyst material that is out of spec can cost them millions of dollars for

A client in the food industry needed to replace a legacy ABB MOD300 distributed control system without stopping production for longer than 12 days.

Our customer’s patented technology is to adhere a dry food/beverage on a substrate. Their first product is a functional beverage printed on a biodegradable cup. The application is a very efficient way to sell and ship products that previously contained liquid in a liquidless format. The liquid is added at