Optimizing OEM Vessel Footprints for Efficient Layouts

A custom, vertically oriented pressure vessel solution helped a medical device OEM cut required floor space by 42% while increasing capacity, improving maintenance access, and maintaining full FDA/ASME compliance. Through precise design, modular skid-mounted vessels, and rapid installation, the project delivered fast ROI, minimal downtime, and a future-ready production layout.

Design Considerations for Optimizing OEM Vessel Footprints

Optimizing OEM Vessel Footprints is critical in modern factory and production line design, where every square inch of space impacts efficiency and cost. A strategically engineered pressure vessel layout doesn’t just save physical space it improves process flow, enhances operational flexibility, reduces safety risks, and simplifies ongoing maintenance. 

At Red River, footprint optimization is a core part of delivering high-performance pressure vessels and modular skids tailored to OEM environments. This case study highlights how a custom vessel solution helped a U.S.-based OEM scale production without expanding its facility footprint.

The Challenge: Limited Floor Space, Expanding Operations

The client, a rapidly growing medical device OEM, needed to increase pressure vessel capacity while remaining within an existing facility. With no option to expand the building, the challenge centered on smart layout design, not brute-force expansion.

Key objectives included:

• Optimizing OEM vessel footprints within existing floor space
• Increasing throughput using compact ASME-certified pressure vessels
• Maintaining compliance with FDA and ASME standards
• Minimizing downtime during installation
• Improving accessibility for inspection and long-term maintenance

This scenario closely aligned with Red River’s experience in custom pressure vessel fabrication for space-constrained OEM facilities.

Engineering Approach: Designing to Fit, Not Force

Red River approached the project holistically, leveraging its full range of capabilities to design a solution that worked with the facility not against it. Rather than forcing a standard vessel into a tight space, engineers evaluated process flow, ceiling height, maintenance clearances, and adjacent equipment.

Key engineering steps included:

• Laser scanning the existing floor layout
• 3D CAD modeling to prevent interference with nearby systems
• Workflow mapping to maintain ergonomic access
• Collaborative design reviews with the OEM’s engineering team
• CFD modeling to prevent dead zones and pressure spikes

This methodology reflects best practices outlined in important pressure vessel design considerations and safety and compliance in pressure vessel design.

Detailed Steps Taken:

• Laser scanning the current floor layout to obtain accurate spatial data
• 3D CAD modeling to visualize potential interference points with surrounding equipment
• Workflow mapping to ensure ergonomic access for operators and maintenance staff
• Collaborative design sessions with the client’s engineers and process control team
• Simulated thermal flow and fluid dynamics modeling to avoid dead zones and pressure spikes in tight piping routes

Red River engineers emphasized modularity, alignment with floor drains, and balance between vessel height and ceiling clearance crucial in OEM environments with overhead HVAC and conduit systems.

Design Choices: Functionality in a Smaller Footprint

The final configuration featured three vertically mounted vessels designed to maximize internal volume while minimizing floor usage an approach commonly recommended for industrial pressure vessels in constrained environments.

Key Design Elements:

• Vertical orientation with elliptical heads (see common pressure vessel head types)
• Side-mounted manways and instrumentation for wall-facing installation
• Skid-based construction using Red River’s prefabrication expertise
• Optimized nozzle orientation to reduce piping complexity
• Steam- and chemical-resistant jacketing for CIP compatibility

This design resulted in a 42% reduction in required floor space, outperforming the original horizontal layout while preserving capacity.

Installation: Rapid Deployment with Minimal Downtime

Red River handled fabrication, logistics, and field support, streamlining installation through a modular, plug-and-play approach aligned with modular skid systems.

Installation highlights:

• Pre-skidded, factory-tested vessels
• Weekend crane installation to avoid production impact
• Wireless sensor integration with SCADA
• Pressure testing and automated safety trip validation

The plant returned to full production in under 72 hours demonstrating the operational advantages of pressure vessel manufacturing done right.

Results: Efficiency, Space Optimization, and Long-Term ROI

The client achieved significant benefits by optimizing pressure vessel footprints in OEM layouts:

• 42% footprint reduction freed up space for future expansions
• Improved production flow with uninterrupted pathways for raw material transport
• 25% shorter maintenance time thanks to better access points
• Zero OSHA violations during the follow-up safety audit
• Projected ROI in under 14 months, based on increased throughput and reduced rework

These outcomes reinforce the importance of quality assurance in custom pressure vessel manufacturing and early collaboration between OEMs and fabricators.

Optimizing Pressure Vessel Layouts A Smart Investment

Optimizing OEM Vessel Footprints is about far more than saving floor space it’s a strategic move toward greater efficiency, improved safety, and operational excellence. In both legacy system upgrades and new facility builds, optimizing OEM vessel footprints early in the planning phase can lead to significant savings in time, cost, and compliance complexity. By aligning vessel design with layout considerations from the start, OEMs can avoid costly retrofits and streamline future expansions. With custom vessel configurations and expert integration, optimizing OEM vessel footprints becomes a powerful way to future-proof operations and support sustainable growth in an increasingly competitive industrial landscape.

Need a reliable partner?

Red River specializes in the design and manufacturing of pressure vessels. We also fabricate related items such as prefabricated spools and skid packages.

Reach out to us today and experience the Red River difference. Where American-made products and American Values come together, we care more.

Frequently Asked Questions 

1. Why is footprint optimization important in OEM facilities?

It ensures efficient use of space, supports safer workflows, and allows room for future expansions or automation.

2. How can vertical vessels improve layouts?

Vertical vessels conserve floor space and can be placed closer to walls or between workstations, improving overall factory flow.

3. Are skid-mounted vessels ideal for OEMs?

Yes, especially in facilities that may need to relocate or upgrade equipment. Skid-mounting offers mobility and modularity.

4. Can existing layouts be retrofitted with optimized vessels?

Definitely. With laser scanning and 3D modeling, new vessels can be designed to match exact facility dimensions and process needs.

5. How does Red River support OEMs in layout planning?

Red River provides full-service support, including design consultation, CAD simulations, fabrication, and logistics coordination.

Key Takeaways

• Optimizing pressure vessel footprints in OEM layouts improves space, safety, and efficiency
• Collaborative planning is key to successful integration without disrupting operations
• Modular and vertical vessel designs are ideal for space-limited environments
• Skid-mounted systems add flexibility and simplify relocation or upgrades
• Partnering with experts like Red River ensures code compliance and long-term performance gains