Engineering

Morgan’s expert engineering teams rapidly respond to deliver tailored solutions for both short and long-term client engagements

At Morgan Consultants, our expert engineering teams are designed to respond quickly and efficiently to your specific needs. Whether you require short-term support or a long-term partnership, we deliver customized, value-driven solutions that seamlessly integrate with your operations. Our lean and highly efficient teams execute your projects with precision and agility, driving success for both immediate and ongoing engagements.

  • Process Development & Engineering

  • Process & Packaging Engineering

  • Commissioning

  • Line Capacity Assessments & Optimization

  • Troubleshooting

  • Infrastructure Systems

Contact Us
404-373-5320
Brewery piping and equipment in a factory

Comprehensive Engineering Solutions for Food Processing and Packaging

At Morgan Consultants, we take a strategic, all-encompassing approach to engineering that drives successful outcomes at every stage of the project lifecycle. Our deep expertise in the food industry allows us to deliver tailored solutions that meet the unique needs of your business.

We apply Stage-Gate methodology to guide your project from early process development through conceptual design, preliminary and detailed engineering, construction, installation, and final commissioning. Our focus is on creating practical, value-engineered, and sustainable systems that align with your company’s success criteria and long-term goals.

Our engineering teams excel in identifying and solving issues before they have negative cost implications. With years of experience across diverse engineering functions, we are equipped to:

  • Quickly diagnose root causes
  • Implement proactive solutions to mitigate future risks
  • Seamlessly integrate into your team, providing expertise from system troubleshooting to new line design and commissioning

In addition to our technical expertise, we offer a comprehensive range of services, including:

By blending practical engineering with a commitment to long-term solutions, Morgan Consultants designs engineering systems and operations that are efficient, safe, and future-ready.

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Driving Results through Project Completion

Operational Assessment & Infrastructure Redesign

A small, privately-held company approached Morgan and requested assistance with developing a project for a new cracker line to increase their capacity. After the scope was approved, Morgan found used equipment that could be modified to fit the application, prepared detailed design that fit the line into the leased space, obtained building permits, arranged for the equipment installation, and provided operations specialists to commission and startup the line. The production capacity of the new line has exceeded client targets.

Raw material system upgrades

Provided Conceptual Design, Preliminary Engineering and CAPEX Budget Development, and Detailed Engineering to double the flow rate of both flour and sugar to several dough mixers in a snack bakery. The bulk silo room had 4 flour silos and 2 sugar silos, and was housed within the main bakery building. The controls system for the bulk unloading and transfer system, and the mixing operations were antiquated. The Bakery operation had experienced lost production time during the mixer cycles due to the limitations in the existing design of the Bulk Flour and Bulk Sugar delivery systems. The upgrades included scale bins, transfer bins, blowers, sifters, and piping. In a separate project, Morgan provided a safety assessment of the equipment and infrastructure to identify improvements needed for compliance with OSHA Dust Explosion Prevention standards.

Tortilla Line Commissioning - Process Troubleshooting

A major snack foods manufacturer was in the process of executing a capital project to install and commission a new Tortilla Chip operation, with the major unit operations designed and provided by the OEM. After 9 months of commissioning efforts by the client’s teams, the OEM, and industry experts performing troubleshooting, the line was only operating at 50% of the OEM’s expected rate. The client solicited technical support from Morgan’s SMEs in R&D and Processing Corn Tortilla Chips to conduct an initial operational and quality assessment and make short-term and long-term recommendations for equipment, materials, data collection, and SOP’s. Morgan quickly engaged a Sr Process Engineer and a Sr R&D Scientist to handle two major work streams in parallel, expediting the overall line operations turn-around.Morgan’s team conducted an initial Operational Assessment to better understand the capabilities and limitations of the equipment and raw materials. This led to optimized raw material specifications and replacement of undersized OEM designed equipment, and formulated methods and action items to maximize product throughput at each unit operation. Based on the operational limits identified in the assessment, Morgan determined that a line re-design was the practical solution to achieve target production rates in an expedited manner. Morgan’s SMEs provided recommendations for improvements, collaborated with the client’s team and the OEMs for the implementation of the modifications, and provided long-term operational support to implement the recommended changes.