When one of the world’s leading food manufacturers decided to renew and relocate their cooling installations, the goal was clear: improve system reliability, increase cooling redundancy, and eliminate costly rental units. The challenge? Executing the upgrade within a large, operational plant where space is tight and every production line depends on continuous cooling. 

At Cyclops, we were asked to take on the basic engineering for the new cooling water network, linking new cooling installations with existing consumers. The project demonstrates how thoughtful engineering and agile project management can turn a technically complex assignment into a smooth, future-proof solution. 

 

1. Understanding the cooling challenge 

Food manufacturing relies heavily on stable, efficient cooling to maintain product quality and food safety. Over time, production sites grow, equipment gets replaced, and temporary solutions pile up, creating fragmented, inefficient systems. 

In this case, the client’s existing cooling network was spread out across the site. Rental units were needed to maintain operations, and energy efficiency was suffering. The new plan aimed to centralize the cooling unit assembly, improve control, and add redundancy to protect against downtime. 

Cyclops’ scope focused on connecting the new cooling towers to existing consumers, designing the piping, vessels, pumps, and instrumentation that make up the backbone of the system. 

 

2. From concept to constructability 

On-site engineering 

Our project manager and technical experts were on site daily to map the as-built situation. Using existing P&IDs and documentation, we verified every connection point and assessed the physical space for new piping routes. Working in a live production environment meant constructability was as important as process design. 

Smart layout and maintenance access 

Ease of maintenance was a top priority. The layout design considered not only pipe routing but also access for future servicing—because reliability doesn’t end at commissioning. 

Data-driven sizing 

We performed pressure-drop and pump-sizing calculations to ensure optimal flow rates and energy efficiency. This avoided oversizing equipment and guaranteed sufficient cooling capacity under all operating conditions. 

Preparing the RFQ 

The final deliverable was a complete Request for Quotation (RFQ) package for the system integrator, including: 

• Basic P&IDs 
   

• Detailed layout drawings 
   

• Piping and pump calculations 
   

• Clear scope definition for execution and commissioning 
   

This documentation allowed the client to start their tender process with confidence and technical clarity. 

 

3. Aligning expectations and managing change 

No engineering project is without its hurdles. Midway through, the client’s project lead changed, bringing new expectations regarding deliverables and timing. This could have delayed progress, but the Cyclops team handled it through open communication, documented scope alignment, and timely updates to all stakeholders. 

By staying focused on the agreed outcomes and maintaining flexibility, the project was realigned and completed on schedule, enabling the client to move forward without delay. 

 

4. Lessons from the field 

Projects like this reaffirm the fundamentals of efficient CAPEX delivery: 

• Capture all agreements in formal scope documents and minutes of meeting. 
   

• Communicate early when expectations shift, transparency avoids frustration later. 
   

• Design with the operator in mind: a good layout saves countless hours in maintenance. 
   

• Stay calm and solution-focused, especially when stakeholder changes occur mid-project. 

 

5. Preparing for your next cooling project 

Efficient cooling systems in food manufacturing aren’t just about equipment, they’re about integration, control, and lifecycle performance. The right preparation in the early stages of engineering determines how smooth the tender and construction phases will be. 

If you’re planning a CAPEX project involving process cooling, start by ensuring your RFQ is ready for the market.