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Manufacturing Process Improvement Projects


Following are examples of Manufacturing Process Improvement projects EFI Group has completed:

  • Design and project planning for anode cover blending and transport systems – Two separate plants
  • Investigate and provide design for offloading and containment problems for aluminum tri-fluoride
  • Investigate and improve design for cable tensioning for ship unloading “clam”
  • Design improvement of blades for proprietary crushing machine
  • Investigate and implement anode positioning system
  • Reconfigure the hot oil/pitch system for green mill
  • Analyze “Arc Flash” report and develop Implementation Plan and capital cost estimate
  • Investigate and develop options for capture of alumina “super fines”
  • Investigate numerous large screening installations to improve maintenance and dust collection
  • Process flow and development of sizing & drying sand as Fracking Proppants
  • Wet resizing process development and project scoping for high purity silica
  • Design of custom extraction system for feldspar dewatering vats
  • Reconcile and improve performance of a flash tube and a fluid energy dryer
  • Evaluate and recommended improvements for dust collection system for fluid energy dryer
  • Raymond Mill throughput analysis
  • Develop strategy and system for balancing and maintaining the inventory of thickener tanks
  • Investigate substitution of HF acid for proprietary process
  • Investigate and develop approach for improving liquid ring vacuum blower installations
  • Design and installation of an 80 tph dense phase pneumatic conveying system
  • Determine improvements to dust collector bags to improve overall performance
  • Redesign of various portions of a continuous processing shingle line – entry and exit end
  • Redesign and replacement of Cooling Section including drive and controls upgrades
  • Investigate and reconcile the performance of fluidized hot oil limestone heater – Two lines
  • Designed and installed many sizes of “Fourdriniers”
  • 225 in paper machine rebuild including the wet end and the winder
  • Paper machine building ventilation evaluation and improvement
  • Optimize stock preparation for color changeover reduction
  • Improving/upgrading paper control systems including: Bleach Plant; Top Lip; Liquor extraction; Clothing Guide controls; etc.
  • Designed and installed synthetic liquor system
  • Development of operating procedures and a training manual for a custom printing process for food packaging
  • Investigated and modified pulper to achieve reduced cycle time
  • Designed powered top lip adjustment mechanism
  • Investigate automated steel carrier roll cleaning mechanism
  • Investigated and installed upgraded dust collector for “coating kitchen” for coater
  • Designed and installed numerous floor roll dollies
  • Design of a narrow web converting line expansion to improve tension control, die registration, and machine flexibility to produce different products
  • Failure mode analysis of chilled roll system
  • Investigate sanitizing procedures/methods
  • Designed and installed dust collection system for dry blending
  • Investigate and configure central vacuum system
  • Configuration of numerous palletizers and pellet baggers – Six installations
  • Developed coal handling/storage configuration
  • Developed automated feed for two stoker type boilers
  • Developed solutions for containing dust for fly ash loading into trucks
  • Design of a potassium chloride storage, conveying, screening, and packaging system
  • Restore proper operation of large existing dust collection system – Two systems
  • Constraint analysis and recommendations for improving sugar distribution to various packaging equipment. Improved productivity by 10%
  • Ion Exchange Project Development including: Plant Layout and Process Flow; Environmental requirements; Preliminary Cost Estimate and Preliminary Justification
  • Conveying equipment design analysis to improve total product flow and equipment reliability
  • Numerous plant layout projects for packaging systems including sugar delivery systems and the configuration of structural towers and mezzanines.
  • Performed FMEA and developed a repair method for vibratory screener supports
  • Investigated, evaluated, and installed moisture sensing transducers
  • Develop the configuration and mechanical design details required to implement chemical suppression and isolation equipment on dust collectors, powder mills, and bucket elevators.
  • System and collection point design and equipment layout including elevated enclosure for several new dust collectors
  • Investigate and solve process problems for two large hydronic systems
  • Investigate and estimate altering process
  • Designed mixing and bottling station associated with a plant expansion
  • Investigate, design, and implement upgrade of biomass filter used for odor control
  • Investigate low line utilization for high speed bottling line
  • Investigate dust capture for proprietary cryogenic grinding process
  • Investigate and design of proprietary sauce production line
  • Equipment selection, line layout, and cost estimate for product conveying, case sealing, palletizing, and wrapping equipment
  • Problem/Opportunity resolution on Rice Vinegar filling line resulting in 45% rate improvement
  • Process Improvements for beverage concentrate filling line
  • Develop process and scope of work for power distribution to support additional flavor manufacturing cell
  • Investigate, design, and execute HVAC upgrade for pilot plant clean room
  • Investigate, design for the heating and cooling for purified water storage system
  • Design and manage installation of load cells for gravimetric batching
  • Design FDA environmental chamber
  • Replacement of processing tanks
  • Design of flammable storage room
  • Removal/replacement of alcohol storage tanks
  • Specify, source and start up reagent filling line
  • Investigate and detailed design for two kiln cart transfer systems
  • Designed automated insulator cut-off operation
  • Investigate and develop design changes for alignment fixtures
  • Design and implementation of new scrap handling system
  • Reconfigure warehouse/packing area
  • Investigate, configure, and design proprietary cement mixing area
  • Design of proprietary bend testing machine
  • Redesign of tooling for proprietary shaping hardware
  • Design and implementation of a custom manipulator
  • Design and implement hydraulic systems for retrofit onto existing manipulator arms
  • Design of new drive and bearing arrangement for pug mill and extruder
  • Design and implementation of a custom cable driven dumping cart for loading an extruder
  • Develop system requirements, design, and implement a closed loop cooling system for extruder and liquid ring vacuum blower
  • Mechanical design of various fixtures as well as redesign of failed mechanical components
  • Automation of laminate samples manufacturing
  • Renovation of hydraulic system for large laminate press
  • Repair of large high pressure high temperature hot water system
  • Plant wide lockout documentation
  • Installation of replaceable floor mounted rails
  • Analyze and redesign large traveling vertical lift
  • Relocate and reconfigure finishing operation
  • Design and implement modifications to reverse roll coating machines and liquid delivery systems
  • Implement new tension control and web guiding systems on Kraft paper machine
  • Drive replacement and tensions control improvements to an existing coating machine
  • Investigate noise reduction for shot peening equipment
  • Design of conveying belt in high temperature heat treat oven
  • Evaluate paper unwind improvements for continuous process
  • Design of fabrication facility for engineered stone product
  • Process investigation to reduce yield loss
  • Configure and design relocation of finishing line
  • Investigate installation of thermal oxidizer
  • Analysis and design for new plant wide compressed air and process sparging air system
  • Perform plant water balance for use of public water resulting in $700,000 credit
  • Design and installation of PLC based process and safety control systems
  • Design and installation of environmental control equipment and systems
  • Investigate alternate source of combustion air for rotary kilns
  • Investigate and arrange for trial test for new source of neutralizer
  • Perform feasibility study for proprietary process
  • Develop concept for reading bar code labels
  • Investigate wire forming problems for paint can handles
  • Investigate wash/rinse water treatment for discharge to public sewer
  • Investigate de-palletizing improvements
  • Designed and complete manufacturing consolidation and reorganization
  • Develop swarf handling solutions for numerous horizontal trenches
  • Reconfigure small parts manufacturing process
  • Design actuated enclosure openings for large shot blaster
  • Investigate improvement and implement for waste water treatment plant
  • Investigate site utility consumption
  • Investigate numerous machine guarding improvements
  • Design proprietary vessel drying system
  • Design proprietary vessel pressure testing system
  • Develop basic system design, equipment specifications, and cost estimate for a pressure test station
  • Multiple steel coating line projects for expansion and improvements
  • Investigate and design process controls for high drying oven w/flammable solvent
  • Analyzed production growth plans; Developed warehouse and shipping work processes and storage arrangement to improve Lead Time and Customer Service
  • Rupture disk selection and design for multiple mixers including catchment tank design
  • Design and implement mixer inerting sensing system
  • Design and implementation of inert solids transfer system for mixers
  • Investigate configuration of compact winding system
  • Reconfigure laboratory electrochemical plating line
  • Improve ergonomics of releasing a frozen ingredient from a fiber drum and design proof of concept solution
  • Project management and machine/structural design for new dredge machinery
  • Preliminary design of pump test facility
  • Develop alternate production line concepts
  • Revise and reconfigure arrangement for existing process lines
  • Prepared P&ID’s for Process Safety Management documentation
  • Site expansion Planning including “Critical Area” requirements
  • Installation of truck scales
  • Investigate handling problems in mix room
  • Establish NFPA rating for compounding room
  • Develop process hardware for proprietary process
  • Develop mold release process for proprietary product
  • Design of custom ventilation systems for large electric motors for compressor stations – multiple locations
  • Design storage warehouse storage arrangement for raw materials and finished goods in support of a plant expansion
  • Investigate de-bottlenecking of proprietary slip casting operation
  • Design for installation of a ceramic kiln
  • Develop process and costing for emergency handling of Powder River Basin coal storage
  • Design of fuel distribution system
  • Process development and cost development for the manufactur of NiAl catalysts
  • Process flow, site plan and costing for the operations to manufacture fluid cracking catalysts
  • Establish plant wide configuration of tube forming, base printing and screen printing to improve efficiencies and reduce costs and WIP
  • Develop procedures for recover of waste plastic from a blow molding operation
  • Site Selection, Relocation & Start Up of warehouse and assembly operations
  • Industrial engineering documentation and configuration of work cells
  • Designed and installed venturi scrubber system to capture acid mist
  • Designed and supervised installation of a 35 acre industrial waste landfill
  • Developed the design concept and final design for pH control for waste water systems
  • Designed custom machine guarding for custom for high speed paper and film handling equipment
  • Custom machine guarding for numerous milling machines and grinders used in the manufacture of industrial air conditioning systems
  • Locker room improvement study tied to the conversion to company provided work uniforms.

EFI Group is a manufacturing engineering firm practicing process engineering, process design, design engineering, manufacturing technology and engineering services. EFI Group is based in Baltimore, Maryland (MD) and serves clients throughout North America.