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Case Study

New pet resin manufacturing facility allows for expansion

Every Challenge Has a Backstory

A leading international manufacturer of polyethylene terephthalate, or PET, resin chips looked to expand North American production by building a new manufacturing plant adjacent to an existing raw material supply facility in Alabama. The company’s goal for the new facility was to increase global production by 500,000 tons of resin chips per year for food and beverage containers, using PET manufacturing technology that is cost-effective and water and energy efficient. 

OBG’s Focus on Solutions

PENTA (an OBG company) provided complete structural, HVAC, and non-process electrical engineering and design services for a greenfield PET resin chip facility on a 40-acre site that was constructed on an extreme fast-track basis. The project comprised building a complete plant adjacent to an existing plant and leveraging raw material supply of TPA (terephthalic acid) and ethylene glycol at the adjacent plant site.

PENTA’s design included a process building, warehouse, utilities and maintenance buildings, plant-wide pipe racks, tank farms, raw material and finished product silo support structures and foundations, rail and truck loading and unloading, and a rail yard.

Results that Matter

The new $190 million facility uses advanced PET manufacturing technology to produce low cost PET resin chips using less energy and water than a comparably-sized conventional PET facility. Due to this low use of energy and water, and the plant’s existing recyclability, the company’s PET has less impact on the environment than either glass or aluminum. The new plant quickly met its initial production goals, and PENTA assisted the client in designing and installing a flake-to-resin process to blend recycled PET resin into the chip production, furthering the client’s ambitious sustainability goals.