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Pilot Plant Expansion to Enable Scalable Bio-Based Manufacturing

Client: GreenLight BioSciences

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Re:Build Optimation exceeded our expectations in the execution of our Pilot Plant Expansion Project.  From high quality mechanical and electrical installations, diligent project/schedule management, transparent spend management, and experience operating in Eastman Business Park, Re:Build Optimation is the ideal partner for GreenLight.

Capabilities Demonstrated

  • Pilot plant and utility system integration
  • Structural engineering and equipment retrofits
  • Continuous process system development
  • Automated chemical delivery systems
  • Packaging line infrastructure preparation
  • Cross-functional engineering and field execution

Challenge

A bio-based product manufacturer needed to expand its pilot facility to support a shift from R&D into early-stage commercial production. The project involved activating previously installed process tanks, increasing downstream formulation and packaging capabilities, and integrating safety-critical upgrades, all while working within an active facility where R&D operations were ongoing.

The expansion required a multi-disciplinary scope with tight timelines, rigorous safety requirements, and minimal operational disruption. Key objectives included improving chemical handling, enabling continuous heat treatment, and preparing infrastructure for flexible filling and sealing operations.

Approach

Re:Build Optimation delivered a turnkey plant upgrade, integrating engineering, fabrication, automation, and installation services across multiple workstreams. The team collaborated closely with client stakeholders to sequence work safely and efficiently within the live operating environment.

Project scope included:

  • Utility and electrical tie-ins to bring three existing tanks into service
  • Installation of a new formulation vessel with structural steel reinforcements
  • Deployment of an automated, centralized sodium hydroxide delivery system
  • Development of a Continuous Heat Transfer System (CHTS) for consistent thermal processing
  • Infrastructure upgrades to support a temporary filling and sealing line
  • Compliance with ASME Boiler & Pressure Vessel Code (Section VIII) and API safety standards

Solution

Re:Build Optimation designed and installed a fully integrated pilot plant expansion to support scalable production of bio-based products. Key systems and improvements included:

  • Process Integration: Utility and process tie-ins activated four vessels for formulation and downstream operations
  • Chemical Handling: A welded sodium hydroxide delivery system reduced manual interaction and improved safety through automated control
  • Thermal Processing: A modular CHTS enabled continuous heating, holding, and cooling of product streams with precise temperature control
  • Structural Modifications: Steel supports and floor beam reinforcements allowed for the safe addition of a final formulation tank
  • Packaging Readiness: Infrastructure was added to integrate a temporary filling and sealing line to support early product deployment

All systems were installed within a constrained footprint and integrated into the existing facility without interrupting adjacent operations.

Results

The project successfully transitioned the facility from a pilot-scale lab to a pre-commercial production hub capable of supporting early product launches. With enhanced safety systems, continuous processing capabilities, and upgraded infrastructure, the plant is now equipped to meet growing demand for innovative bio-based products. Re:Build Optimation’s ability to manage complex systems integration in a live operating environment positioned them as a trusted partner for future expansions.

Benefits & Impact

  • Expanded Capacity: Enabled pilot and early commercial production with scalable infrastructure
  • Improved Safety: Automated chemical delivery reduced manual handling risks
  • Process Efficiency: Replaced batch processing with a continuous thermal treatment solution
  • Operational Flexibility: Supported flexible filling and sealing operations for pre-commercial product launches
  • Future-Ready: Delivered infrastructure and utility upgrades that support long-term scale-up plans

System Overview

  • System Type: Integrated utility and process upgrade for pilot-scale bio-manufacturing
  • Function: Supports formulation, thermal processing, and product packaging
  • Key Features: Automated NaOH delivery, Continuous Heat Transfer System (CHTS), structural tank supports
  • Deployment: Retrofit completed within an active U.S.-based production facility
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Title

By: XXX

Client: XXX

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Capabilities Demonstrated

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