Pilot Plant Expansion
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.
Peanut Butter Plant Expansion
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 fabricated and assembled the 68-foot-long machine that met the company’s goal of a cost-effective and efficient washing procedure. The machine was solely produced by Re:Build Optimation from concept to completion, including the electrical, mechanical, material handling, process engineering, design, fabrication and assembly of each sub-system. The new washer has the room to queue up to five incoming kettles and index kettles into an automatic kettle unloader that will transfer the parts from the kettles into washer baskets. The operator delivering the kettle will make push button selections to indicate the product type tote bin and the wash cycle treatment. A washer in-feed conveyor will convey and transfer the loaded baskets into the washer system conveyor, which will take the parts through its cycle. An out-feed conveyor will receive the washed part baskets as they exit the washer and transfer the basket into a basket shuttle dumper, which will then dump the parts from the basket into the desired tote bin. The empty basket then goes back to a return conveyor for queue-up, and the process starts again.
Machine Design/Build – Parts Washer
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 fabricated and assembled the 68-foot-long machine that met the company’s goal of a cost-effective and efficient washing procedure. The machine was solely produced by Re:Build Optimation from concept to completion, including the electrical, mechanical, material handling, process engineering, design, fabrication and assembly of each sub-system. The new washer has the room to queue up to five incoming kettles and index kettles into an automatic kettle unloader that will transfer the parts from the kettles into washer baskets. The operator delivering the kettle will make push button selections to indicate the product type tote bin and the wash cycle treatment. A washer in-feed conveyor will convey and transfer the loaded baskets into the washer system conveyor, which will take the parts through its cycle. An out-feed conveyor will receive the washed part baskets as they exit the washer and transfer the basket into a basket shuttle dumper, which will then dump the parts from the basket into the desired tote bin. The empty basket then goes back to a return conveyor for queue-up, and the process starts again.
New Milk Replacer Production Facility
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 as a supply component for the formula. The process included evaporating whey to a specific concentration, which was then used as an ingredient in producing a slurry which then fed a large dryer. The company needed a turnkey supplier for support of their new 60,000-sq-ft, state-of-the-art facility in Auburn, NY to produce the formula.
Manufacturing Vaccine Delivery Systems
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 the Department of Defense, to make the vials for COVID was located in Auburn, AL. That summer they launched a $163 million expansion project to ramp up production of its proprietary vial system. The company needed to have special machines built, each 130 feet long and armed with sensitive cameras to detect defects or contaminants, to mass produce the vials. The facility was to have 10 production lines, each capable of turning out 15 million vials and syringes per year. Their patented materials science was a combination of a plastic container with a microscopic, thin, undetectable to the naked eye, pure glass coating for biological drugs and vaccines. The syringes were precision molded and up to 15 times more dimensionally consistent than glass, enabling error-free operation with autoinjectors and other drug delivery devices.
High Pressure Test System – Simulating Deep Well Conditions
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 under the earth’s crust.
Heat Treat Line Installation
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 nothing was labeled and there were no drawings for the installation of the machines.
Fuel Cell Test Stands
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 aerospace equipment. This technology uses the chemical energy of hydrogen to cleanly and efficiently generate electricity. As an alternative energy source, hydrogen fuel cells produce only water and heat as waste products – a significant improvement compared to the greenhouse gases produced by traditional fossil fuel combustion-based technologies.
A prominent fuel cell and hydrogen manufacturing company approached Re:Build Optimation Technology to develop test equipment to support their production of hydrogen fuel cells and related equipment such as electrolyzers.
Fluid Flow Analysis
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 included the addition of a secondary cooling system, along with significantly increasing the pumping capacity These upgrades were originally estimated in excess of $250,000.
Emergency Steam Leak Repair
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 local chemical/film company in late 2013 and has been working on infrastructure upgrades since then.
The utility company’s operations manager called Re:Build Optimation’s construction manager, Jack Burke, for an emergency meeting after a 70 lb. steam main had fractured beneath Lake Avenue. This line supplied steam to a neighboring company, causing the company to shut down operations. Both the neighboring company and the utility company became concerned about cold weather causing sprinklers to go off and damage operations and research in the neighboring company’s production facility.
The objective: fix the steam main and get utilities back up and running to the neighboring company ASAP.