Project Scope:
The project included full MEP design for the processing, testing, and recycling laboratories, large-scale extrusion and grinding operations, washlines, and support spaces. The facility encompassed over 268,000 square feet of heavy industrial space, including:

• Extrusion lines
• Washline systems
• Testing laboratory for process quality control
• Heavy-duty electrical distribution and backup systems
• Extensive plumbing and process cooling infrastructure to support the processing lines.

Design Challenges:

• High Power Demand: The facility required over 20 MW of electrical capacity to support industrial equipment, necessitating design and coordination for seven (7) 5,000A 480V main switchboards.
• Vendor-Driven Coordination: Extensive and early-stage collaboration with multiple international equipment vendors was critical to properly design power, mechanical, and process utility connections.
• Process Water and Reuse Systems: Implementation of high-volume water systems with dedicated filtration, treatment, and reuse capabilities to support washing and cooling operations.

Mechanical and Plumbing Systems:

• Two (2) 250-ton air-cooled process chillers supporting extrusion cooling.
• Multiple booster pump systems, primary and secondary chiller pumps, and process water systems.
• Break tanks and booster pumps for domestic and process water isolation and pressure maintenance.
• Comprehensive lab-grade plumbing infrastructure including RO/DI water loops, wastewater drainage, and floor drainage design accommodating plastics waste by products.
• Fire protection water storage tank and fire pump system sized for large industrial hazard classification.

Electrical Systems:

• Design and coordination of 20 MW total power distribution.
• Seven (7) 5,000A 480V switchboards (Main Switchboards MSB1–MSB7).
• Coordination with utility provider for extensive primary power infrastructure, pad-mount transformers, and underground primary systems.
• Detailed panel and feeder design for equipment rated from 480V three-phase to 120V convenience power.
• Dedicated critical branch systems for process control and life safety systems.

Forensic and Problem-Solving Aspects:

• Early forensic review of equipment loads and utility needs, identifying discrepancies in vendor-provided requirements, leading to critical adjustments ahead of construction.
• 3D BIM modeling of all MEP spaces to resolve extremely tight clearances for conduit banks, chilled water piping, and process piping.
• Custom-designed grounding systems to support equipment sensitive to static discharge during plastics processing.

Outcome:
The facility was successfully transitioned to Waste Management as part of their Natura PCR acquisition, serving as a cornerstone of WM’s plastics recycling initiatives. GK Engineers’ early coordination efforts, adaptability to evolving vendor equipment requirements, and comprehensive utility planning were pivotal to the project’s success.