Project Overview
This project involved the expansion of an existing malt production facility through the addition of a new kiln system. Located in Winona, Minnesota, the development included civil, structural, and mechanical work to support the integration of kiln vessels and associated process systems. The new infrastructure aimed to enhance drying capacity and improve the overall efficiency of malt production.
Project Goals
The primary goal was to increase production throughput by incorporating an additional kiln unit into the facility. This required the construction of specialized support buildings and structural components, as well as the installation of conveyance systems to seamlessly integrate with existing operations. Maintaining plant functionality during construction and coordinating with multiple contractors were also essential objectives.
Technologies and Innovations
Several key components and technical strategies were implemented to deliver this complex addition:
- Construction of reinforced concrete foundations to support the weight and operational vibration of the kiln and fan buildings.
- Erection of the fan building superstructure, including structural steel framing and mechanical systems to support ventilation and temperature control.
- Roof structure, insulation, and cladding were carefully installed around the kiln vessels to ensure thermal efficiency and long-term durability.
- Structural ducting within the fan building was precisely fabricated and installed to support airflow control critical to the malting process.
- Product conveyance and reclaim systems were added to streamline material handling, increasing overall plant automation and reducing manual labor requirements.
- Erection assistance for kiln vessels required specialized rigging and coordination to align heavy equipment into place safely and accurately.
Results
The kiln addition was completed successfully, with all components integrated seamlessly into the existing facility. The project improved malting capacity and energy efficiency, while the upgraded mechanical systems enhanced control over drying cycles. Minimal disruption to ongoing operations was achieved through detailed planning and close collaboration between field teams and plant operators.
The malt plant kiln addition in Winona, Minnesota, represents a successful expansion of production capabilities within a live processing environment. The project brought together precise civil works, advanced structural integration, and mechanical innovation to support increased output while maintaining operational stability and efficiency. This enhancement positions the facility for improved performance and future scalability.
