FWS was commissioned to design and construct a new facility to house a 24-metric-ton cooker, replacing an aging unit. The project demanded seamless integration of specialized equipment, a structurally sound foundation, and precise procurement strategies to meet strict deadlines. FWS led the shop fabrication and hydro testing of process piping before delivery, and was responsible for the installation of structural piers, steel structures, conveyance systems, registered piping, and electrical components, including motors, VFDs, and power distribution systems.

The key objectives of the project were to:

• Match the existing cooker’s capacity by ensuring the new system effectively elevated flaked seed temperatures for optimal extraction.
• Optimize project scheduling to mitigate delays and maintain efficiency despite unforeseen challenges.
• Self-perform the cooker installation, reinforcing FWS’ design-build expertise and reducing reliance on subcontractors.

FWS employed a strategic approach to maintain efficiency and overcome schedule disruptions:

• Advanced Execution Planning: When the owner-supplied equipment arrived two months late, FWS quickly adapted its execution strategy, ensuring minimal impact on project timelines.
• Optimized Workforce Management: By doubling key crews, steel erection was completed three weeks ahead of schedule, and process piping installation was finished two weeks early.
• Accelerated Work Schedules: The introduction of overtime work further compressed the timeline, allowing FWS to regain an additional two weeks and bring the project back on track.

Despite supply chain setbacks, the project was completed successfully within the revised timeline:

• Efficient Construction Execution: Structural and mechanical installations were completed ahead of schedule, minimizing overall delays.
• Enhanced Processing Capabilities: Richardson International can now efficiently replicate its existing infrastructure, ensuring smooth operational continuity.
• Demonstrated Design-Build Expertise: FWS' ability to self-perform cooker installation, typically subcontracted, showcased its end-to-end project execution capabilities.