Avery Denison, Design Build Coater Installation Expansion, Mentor, OH
Middough provided an extensive array of services on this $4.5 million, 50,000 SF plant and office expansion including facility planning and general arrangements. An environmental survey was completed with wetlands delineation and mitigation permitting with the site requiring an additional stormwater retention basis. All necessary documents for the Storm Water Pollution Prevention Plan (SWPPP) were prepared and submitted by Middough. The building expansion included a mechanical and electrical room housing a 400 ton chiller with cooling tower and a dual 80/60 hp clean-steam boiler system with the electrical specifications for a 2,500 KVA secondary unit substation and power distribution.
Materion, Beryllium Manufacturing Plant (formerly Brush Wellman), Elmore, OH
Brush Wellman has retained Middough to design a new $90+ million facility that will produce primary beryllium, the feedstock material used to produce beryllium metal products. The new facility represents a key step toward the return of a sustainable domestic supply, critical to the nation’s strategic interests.
The new facility has been designed with state-of-the-art safety features and will be heavily automated. The facility design is unique in that it incorporates traditionally separate functions into one facility. The design integrates process plant and chemical operations with food science and clean room standards. This blend of requirements and capabilities challenged Middough’s HVAC designers to provide a system capable of meeting diverse, and at times, divergent needs.
Also woven into the facility design is a robust material handling component that efficiently
handles the Beryllium material as it passes through the facility. The process is highly hazardous,
requiring completely closed design exceeding the requirements for active pharmaceutical
intermediates, while working in an HF acid environment and with furnaces operating at up to
1400°C. The processing involved an extensive wet chemistry section to remove impurities to
the ppm range, continuous evaporative crystallization and a continuous dryer system. The
intermediates were extremely hydroscopic and decomposed with high temperatures. Following
were a series of high temperature induction furnaces and decomposition product recovery,
purification and recycling. A goal was to render waste products benign before they entered
the operators’ environment and to be a near zero water discharge plant.
Confidential Client, Charleston, SC
Middough has continuously provided engineering service projects from production equipment design, automation upgrades, industrial engineering studies to full scale engineering, procurement and construction management (AEPCM) services for new production facilities and plant expansions.
Middough provided AEPCM services for their new 210,000 SF production facility in Charleston, South Carolina. Over 60,000 SF of this facility was designed as a critical controlled clean room environment that required specialized air and water handling systems. Within the facility Middough also designed 20,000 SF clean room laboratories and 30,000 SF administrative spaces. Since the project was so unique, it required numerous specialty equipment placements and contractors. Middough prepared, procured and managed 110 separate construction contracts and over 430 equipment and material specifications.
Owens Corning, Cultured Stone, Chester, SC
Middough as an Alliance Partner, has provided engineering services to Owens Corning for over 10 years. Projects have ranged from environmental projects including dust collection and regenerative thermal oxidizer upgrades, automation projects with focus on energy consumption reduction and equipment optimization, relocation, consolidation and rebuild projects, packaging / unitizers, capacity studies to full scale engineering, procurement and construction management (AEPCM) services for new production facilities and plant expansions.
Middough provided AEPCM services for a new 225,000 SF cultured stone production facility on a 40 acre Greenfield site in Chester, South Carolina. The project included two production lines with all associated conveyance, material storage and utility systems, paint mixing line, dry color mixing line, dust collection systems, and latex mold layup line for corner and straight molds. Through innovative design, Middough developed a system that essentially eliminated waste water discharge at the plant.