Protein Processing Facility
Scenario
A protein processing company developed a new pork processing facility with refrigeration capacity to support 1200 TR of high-temperature process cooling and 700 TR of low-temperature freezing.
The project was led by a design-build general contractor that Sterling had previously worked with on a similar job. Sterling was involved early in pre-design, supporting the initial process design and later taking on the refrigeration construction scope.
That early start helped keep the refrigeration system aligned with the building as the project moved into installation and startup. The system was brought online in December 2025 and is currently in commissioning, as all processing lines are completed.
This allowed the customer to begin producing USDA product ahead of the original schedule.
Challenges
Like most large industrial projects, this one came with a few moving parts. The team worked through schedule delays, utility limitations, and installation coordination while preparing the facility for startup and ongoing operation.
Equipment and materials were purchased for the original 2023 build schedule, then remained in storage through a delay of more than a year and a half. That added risk around equipment condition and startup readiness.
Delays from the power provider meant the system had to be commissioned under temporary power restrictions.
The refrigeration system required coordination across multiple trades to keep installation moving and avoid field conflicts.
These conditions made communication, sequencing, and coordination especially important across the project team.
Our Solution
During the extended delay, stored equipment was maintained through motor rotation and visual inspections. Additional electrical and mechanical testing was completed before commissioning.
With utility service delayed, the project team commissioned the system under temporary power. Priority equipment was selected to bring on ammonia, pull down cold spaces, and maintain facility temperature while operating under restrictions.
Early involvement helped keep electrical and mechanical requirements aligned across teams. That helped the refrigeration system integrate cleanly into the building and supported commissioning once power was available.
The system was coordinated through Navisworks, with pre-designed piping helping reduce field conflicts and keep installation moving efficiently.
Experienced technicians remained on site to support the customer team through startup, including training on daily rounds, safe pump-outs, and system tuning.
Sterling also provided a complete PSM (Process Safety Management) program and RMP (Risk Management Plan) study, along with step-by-step guidance through registration and implementation.