COVID-19 Design Impact Series |
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Last Spring, many of us became acutely aware of the availability (or lack) of supplies in our local grocery stores, drug stores, and other retailers. The COVID-19 pandemic disrupted the nation’s supply chain for food, medications, and other items we traditionally took for granted in stores. In response, many of us changed our consumption habits. We learned to shop online, pick up curbside, or stock up on goods we worried might become unavailable soon.
As volumes increased, the ability for the existing channels to meet demand became even more challenging, shining a spotlight on our nation’s distribution industry, including cold storage and processing facilities. While many corporations were already looking into replacing outdated regional distribution centers to take advantage of improved technology and building performance, the pandemic accelerated the process. Owners also began looking at adding micro-fulfillment centers to reduce the distance between the product and the end-user. While mega-giants like Amazon have led the headlines for this strategy, the argument for implementing micro-fulfillment cold storage facilities to assure a fresh, safe food product is perhaps even more compelling.
Coming full circle, COVID-19 continues to impact these facilities today as pharmaceutical companies race to produce vaccines, which they then need to store and distribute nationwide.
Whatever the reason, new construction and upgrades for cold storage and processing facilities is expected to continue an upward trend in 2021. In this edition of our COVID-19 Design Impact Series, we’ll talk about our approach to not only designing the mechanical and electrical systems for these projects, but also how we support power generation and distribution, evaluate building efficiency, and assess electrical performance and safety. (Please Note: Names of some project owners have been removed to respect confidentiality.)
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Carving a Niche in Cold Storage |
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Editor's Note: Cloverleaf Cold Storage was acquired in 2020 by Americold Realty Trust, the world's largest publicly traded REIT focused on the ownership, operation, and development of
temperature-controlled warehouses.
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Over the course of more than a decade, West Plains Engineering developed a partnership with Iowa-based cold storage firm Cloverleaf Cold Storage (CCS) that resulted in dozens of projects at sites across the country. The company, which was bought by Americold in 2020, was originally founded in 1952 and owned 22 facilities and 132 million square feet of refrigerated space nationwide.
When we started working with CCS, we relied on our history with manufacturing and processing spaces as a strong foundation and grew in our understanding of the complexities and intricacies of cold storage spaces with Cloverleaf. Over time, we gained experience and insight that made us a trusted advisor to CCS through multi-million dollar new facility construction, expansions and remodels of aging spaces, and frequently, short circuit, coordination, arc flash, power factor correction, and thermographic studies.
Throughout, our team supported not only the mechanical and electrical design for these spaces but added value by performing electrical safety review and mitigation which is crucial in such a highly regulated industry.
In addition to their 22 cold storage warehouses, CCS had four food-grade ambient temperature warehouses and four custom food processing facilities.
Obviously, a clear focus for the facility design centered around refrigeration. These designs typically included various sizes of ammonia compressors (700-300HP) with various evaporators throughout the refrigerated space and exterior condensing units. In-floor glycol heat loop systems keep the floor from freezing, and an ammonia detection system that exhausts the spaces, shuts down compressors, and at high levels, will shunt trip the plant electrical distribution system.
Electrically, the electrical services to serve cold storage are always large and range from 5000-3000A - sometimes including multiple services. The lighting systems include bi-level LED fixtures with occupancy sensor control and computer monitoring and metering. Power factor correction was typically installed to avoid utility company demand penalties. Floor temperature sensors, ammonia sensors, air temp sensors, wireless access points, access control, and security cameras are some of the special systems these facilities require. Lastly, the entire facility has a wireless RF antenna system for easy bar code reading.
Since CCS joined the Americold network, our relationship with these facilities and staff has remained strong. In the past two years, we have performed four projects for Americold in Ohio, Virginia, and Illinois.
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Todd Weidner, P.E., CESCP, RCDD is an Electrical Engineer and manager of the WPE Electrical Specialties Division. Todd has been the Project Manager and Lead Electrical Engineer for nearly all of WPE's work with CCS, including performing all of the electrical safety studies and mitigation efforts.
Todd is both a Certified Level 1 Thermographer, as well as a Certified Electrical Safety Compliance Professional (CESCP).
He has been with West Plains Engineering since 2000.
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Strategic Direction Report |
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How Products & Processes Affect Design |
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Considerations for Cold Storage & Food Processing Facilities |
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The article below is an excerpt from a WPE-authored white paper on the design considerations for Industrial & Manufacturing spaces. This section focuses specifically on cold storage and food processing. To download the complete text, including our perspective on spatial challenges, unique environments, specialty equipment, and safety - click here.
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Depending on the industry, the design challenges for cold storage and food processing facilities change slightly. Large warehouses are often concerned with stratification. Manufacturing plants focus on indoor air quality and employee comfort. Food factories, which tend to be the most highly regulated, include all of the above plus added scrutiny toward space temperature, humidity control, and emergency power systems, all of which impact the quality of their product.
In the midst of this, is also the unique task of making sure the mechanical and electrical systems of the facility itself can support the specialized production equipment used in the manufacturing and storage processes. Not to mention - that it can do so in a potentially hazardous environment.
Food production and cold storage facilities must follow perhaps the strictest regulations and design standards in this industry. Beyond assuring compliance with health and safety codes, these considerations are also in place to make sure the product maintains its quality for final sale to the consumer.
No two food production spaces are alike. Each environment requires different manufacturing equipment and storage techniques and consequently needs different mechanical and electrical systems.
In cold storage facilities, the design team must be aware of the temperatures in all areas and design systems that work efficiently together to maintain them all collectively. These can vary from a 45-degree loading dock to a 10 degree cooler to a -30 degree freezer or even blast chillers. Specifying the right equipment for the environment is key to begin with, but careful consideration must also be taken for redundant power systems and battery backup in case of an emergency. After all, losing power in cold storage has the potential to spoil an entire facility’s product in a very short time.
Notably, the cold storage industry has seen a recent shift toward modular rooftop refrigeration systems, as opposed to low-charge ammonia systems or industrial freezers. These rooftop systems don't use water while maintaining the same approximate annual power consumption, which can reduce operational costs for the owner through reduced power and water usage, as well as maintenance.
When designing power and electrical systems, remember that both food production and cold storage facilities require washdown. This additional water in the space means the electrical design must adhere to the proper IP (International Protection) rating. This rating addresses electrical safety protection from the ingress of solid objects and water.
Assessing and analyzing electrical safety shouldn't stop there. The typical industrial facility is typically older (sometimes 50 years or more) with many additions and renovations over time. But even with brand new construction, there are analyses and audits that should take place to assure the equipment, and those running it, are safe.
Most installations have never had an accurate 1-line diagram (or maybe not any at all). The best way to get to an accurate 1-line is to perform an Arc Flash Assessment. In an arc flash study, the 1-line must be determined, which means all equipment will be traced out and inventoried by a qualified engineer along with knowledgeable facility staff and any servicing electricians. One of the common things this study can find is that the equipment is underrated for the available fault current. This can be a dangerous situation. If a fault would occur, it won’t be contained in the equipment, which could catastrophically fail.
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Darrin Tille has been a Mechanical Designer in our Sioux Falls office for more than 10 years. He has been the Project Manager and led the mechanical efforts on numerous industrial projects for cold storage and processing clients such as Premium Iowa Pork, Royal Canin, etc.
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Todd Weidner, P.E., CESCP, RCDD is an Electrical Engineer and manager of the WPE Electrical Specialties Division. He has been the Project Manager and Lead Electrical Engineer for a number of industrial projects, including performing all of the electrical safety studies and mitigation efforts. He has been with West Plains Engineering since 2000.
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Maintaining Safety & Quality With HVAC |
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Since the early 2000s, West Plains Engineering has worked with a national food manufacturer and distributor on a variety of projects at their plants in Iowa and Nebraska. In the past five years alone, this has included five separate projects focused on office, processing, and cold storage additions to existing plants, with our team supporting the HVAC design for these spaces. Our goal for these projects was consistent and straightforward – create mechanical systems that were on budget, easily maintained, and able to support the safety and quality of the company's products and people.
These projects started small. Our first was in 2015 with a 2,100 square foot office addition in Nebraska where we only designed the fire protection system. But over time, our role and the complexity of the projects have grown.
In 2016, our mechanical engineers supported a new two-story cooler expansion, engine room building, trailer wash building, and security building at the company's plant in Iowa. Followed by a 25,400 square foot CO2 stunning room addition in Nebraska a year later. The stunning room supported the company's animal processing and also included an unloading dock, barn expansion, and procurement building. WPE was responsible for the design of domestic plumbing and HVAC for the 2,600 square foot procurement space, as well as ventilation design for the 9,450 square foot barn expansion.
Most recently, we were part of a design-build team on an addition to yet another plant in Iowa. Our mechanical engineers were responsible for the HVAC design to support various components of the new space, including the electrical room, shipping dock office, trash area, slicing control room, grinding control room, and USA space.
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Taking Care of Products...and People |
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Plant Additions & Renovations |
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WPE began working with one of the largest international food manufacturers in the industry in 2019, joining a design-build project for a 51,000 square foot carcass cooler addition, and ancillary support space, for a processing plant in Minnesota. Having worked with Cloverleaf Cold Storage, our team was extremely familiar with the process, equipment, and challenges for expanding these types of facilities – giving us the experience necessary to support a global client.
Mechanically, the HVAC ventilation design consisted of relocating the intake openings and replacing the continuous exhaust fan for the ammonia refrigeration machinery room. We also added an intake and exhaust system controlled by hydrogen sensor and alarm panel serving a battery charging area, electric unit heaters serving ancillary areas, a rooftop unit serving an electrical room, exhaust for a bathroom group, and general exhaust in other areas.
The plumbing design involved adding floor drains with integral cleanout and standpipe drains in two large cooler spaces connected to the existing process waste system. Heat tracing was part of the design for piping routed in the cooler spaces. The existing water softener system, reverse osmosis system, and air compressor were relocated and plumbed with new piping. A new water heater and emergency eye-wash shower were provided with a hot water recirculation system, as well as an existing high-pressure hot water system that was extended to one of the cooler spaces. Piping riser drawings were provided for all systems.
The project was completed in 2020, but our relationship with the owner continues. In 2021, we began working on a series of improvements to the employee welfare spaces at the company's plants in Arizona, Nebraska, and Wisconsin. These projects focus on either additions or renovations to existing spaces within the plants into offices, cafeterias, locker rooms, and other spaces suited to enhance the well-being of the staff. To that end, we are working with the owner to explore options to combat COVID-19 and other viruses through smart HVAC design that will prevent cross-contamination of spaces.
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Nick Carr is a Mechanical Designer in our Sioux Falls office. He joined WPE in 2017 and has been heavily involved in our work with industrial clients. Learn more about Nick (and check out that hair!) in our Team Profile below!
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Title:
Mechanical Designer
Years with WPE:
3 Years
Home Team:
Wife: Emily
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Nick Carr joined West Plains Engineering as a Mechanical Designer in our Sioux Falls office in 2017. He has quickly made a name for himself for our firm, taking on complex mechanical designs for a variety of building types, including industrial spaces, as he works toward his P.E. But that's not the only reason Nick stands out. A 6'8" former offensive lineman for the SDSU Jackrabbits, Nick is hard to miss in a crowd (and equally hard to find a desk that fits)!
Check out our Q&A with Nick below to learn more about how he balanced a demanding education in engineering with his schedule as a Division 1 athlete, what he's learned since becoming a consulting engineer, and his perspective on designing for industrial facilities.
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Why did you want to become a mechanical engineer?
I became interested in physics as a freshman in high school and as I became older, realized I liked when physics was applied and not just in theoretical situations.
How did you balance being both a D1 athlete and an engineering student?
By managing time to the best of my ability, and realizing after my freshmen year I would not graduate with a perfect 4.0 GPA. Also, depending on the semester, I would cut down on the hours of sleep I would get a night.
What have you learned about being a consulting engineer that surprised you? What do you enjoy most?
I came to West Plains straight from school and what surprised me is that a large part of our job as consulting engineers is client service. Similar to sales or any other customer service field, we put forth a lot of effort and personal work with clients to make sure they are happy. It seems obvious now, but it's not really something that is addressed or developed in mechanical engineering undergraduate courses, so it was a bit of a surprise at first.
The piece I enjoy the most is the beginning of the project when you get to first pull together the idea of the systems that will be utilized. Taking that idea, and being able to flesh out the details of the requirements for the systems in that project can be a fun and sometimes challenging puzzle.
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You've worked with several large, industrial clients since joining WPE. What makes these facilities different/unique in terms of mechanical design?
The opportunities when I have worked with industrial clients are usually design-build projects, which has its own set of unique processes. One of the more industrial-specific situations I have come across more than once would be ammonia refrigeration machinery rooms. The machinery rooms have their own set of requirements including varying levels of ventilation, such as continuous, emergency, and temperature control; as well as sensors and an alarm system.
What's your favorite project to date? Industrial or otherwise...
Probably the Siouxland Expo Building. It started out as the Ag-Expo building, the Ag part was eventually dropped off, but before it was, I got to experience some of the design considerations for a space that would be both a standard expo space but also converted to be able to house various agricultural activities and competitions. After the agricultural piece got taken out, it was still a very large building with an arena for sports, a climbing wall area, and office and meeting support spaces. Overall, it was a large project that turned out well and I believe the owner group is happy.
Tell us about your family!
As of right now my wife, Emily, and I do not have any kids or pets. I am originally from the Twin Cities area and I am the oldest of six kids. I have two sisters and three brothers and, yes, we are all pretty large, although I am still the tallest. My parents still live in New Brighton, MN with my two youngest siblings, and the rest of us are kind of spread out in college and/or working.
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West Plains Engineering News |
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Stuart Oster, P.E. Named Mechanical Department Head |
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Mechanical Engineer Stuart Oster, P.E. has been named head of the Mechanical Department in our Sioux Falls office. In this role, he will be critical in the development and delivery of West Plains Engineering’s mechanical engineering services, as well as help mentor staff, support leadership, and establish client relationships.
Stu joined West Plains Engineering in 2013 after working as a consulting engineer in the Sioux Falls area since 2007, and in Minneapolis since 1998. A graduate of South Dakota State University, he is a consistent leader and asset to the firm, managing more than 50 projects and supporting clients such as SDSU, Dakota State University, University of South Dakota, the Department of Veteran Affairs, and multiple East River K-12 school districts. Notably, he was the project manager for the $17.4 million CarsforSale.com Headquarters, as well as a multi-phase, multi-year project making nearly $2 million in HVAC upgrades to the McFadden Northern Plains Biostress Lab at SDSU.
Congratulations Stu!
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In March, Justin Henning celebrated 10 years with West Plains Engineering!
Justin has been a CAD Technician in our Sioux Falls office since 2011. Congrats on a decade and thank you for all you do for West Plains!
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Rapid City Office Holds Humane Society Donation Drive |
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Our Rapid City office held a donation drive for the Humane Society of the Black Hills in March, raising more than $250 and a carload full of supplies! The event was coordinated by Marketing Director Kelli Crouse, and supported by donations of cash, dog and cat food, toys, and various other animal necessities from the team.
Thank you to the staff in Rapid City for their generous participation!
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2021 might have been the BEST E-Week ever!
While we're always proud of our engineers and support staff, this year we were especially excited to spend a week recognizing (and spoiling) them for the incredible work they do year-round.
Our E-Week revelry included daily videos and prizes, and a breakfast at each office. Check out some of our winners below!
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Our first winner was Julie Morton from Casper who won a gas card to a station of her choice...which we've heard might be put toward a concert road trip! |
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CAD Tech Ben Sonichsen was our second prize drawing champ - winning at Instapot! Ben is one of our newest employees, joining our Sioux Falls team last October. |
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Mechanical Designer Dustin Torguson took home a serious haul in restaurant gift cards! Dustin has been a Mechanical Designer in our Sioux Falls
office since 2013.
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The prizes started heating up late in the week, with CAD Tech Vic Stephens taking home a Big Gas Grill! Vic has been with our Rapid City office more than 20 years, and we're still hoping she'll leave the grill at work and cook for us... |
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And the E-Week GRAND PRIZE went to....Jonathan Kennedy! Jon is head of the Electrical Department in our Sioux Falls office, and won our final prize - grocery gift cards.
Congratulations to all our winners, and a sincere thank you to our staff who continue to make our firm what it is!
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Rapid City, SD | Sioux Falls, SD | Casper, WY | Cedar Rapids, IA |
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