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. In this case study, we explore how a custom solution from Red River focused on optimizing OEM vessel footprints helped a U.S.-based OEM achieve these exact goals. The project delivered a compact, high-performance vessel design that integrated seamlessly into the plant layout—without disrupting production schedules or exceeding budget constraints.
The Challenge: Limited Floor Space, Expanding Operations
The client, a fast-growing medical device OEM, faced a common but complex challenge: they needed to expand their pressure vessel capacity without increasing their facility footprint. With production demand rising and no room for physical expansion, the pressure was on—literally and figuratively. Their primary goals included:
- Optimizing OEM vessel footprints to fit within existing floor space
- Increasing pressure vessel capacity to support higher throughput
- Ensuring full compliance with FDA and ASME standards
- Minimizing disruption to existing production lines during implementation
- Enhancing system accessibility for future maintenance and inspection
This case presented an ideal opportunity to demonstrate how Optimizing OEM Vessel Footprints can solve spatial constraints while unlocking greater efficiency and scalability.
Engineering Approach: Designing to Fit, Not Force
Red River took a holistic approach to optimizing OEM vessel footprints, combining advanced design, simulation, fabrication, and logistical expertise to engineer a solution that worked with the facility’s constraints—not against them. By carefully evaluating spatial limitations, process flow requirements, and maintenance access points, the team developed a custom vessel configuration that maximized performance within the existing footprint. This approach ensured seamless integration with the client’s production line while avoiding costly structural modifications or operational downtime.
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 design featured three vertically mounted, ASME-certified pressure vessels—an intentional configuration aimed at optimizing OEM vessel footprints in the constrained facility space. By orienting the vessels vertically and integrating essential control, piping, and monitoring systems into a compact, modular layout, Red River enabled a leaner installation that preserved valuable floor space. This space-saving design not only supported higher production capacity but also simplified maintenance access and improved overall plant efficiency.
Key Design Elements:
- Vertical orientation with elliptical heads to conserve width while maximizing internal volume
- Side-mounted manways and instrumentation panels to enable wall-facing installation
- Skid-based design with anchored vibration-dampening pads for safety and stability
- Optimized nozzle orientation for direct connection with pre-existing piping and reduced need for elbows and bends
- Steam and chemical-resistant jacketing to support CIP (clean-in-place) operations
Together, these features contributed to a 42% reduction in required vessel floor area compared to the original plan.
Installation: Rapid Deployment with Minimal Downtime
Red River handled not only the fabrication but also shipment and field installation. The vessels were fabricated and tested at Red River’s facility, then:
- Delivered in pre-skidded, sensor-calibrated units
- Installed over a single weekend using overhead cranes and plug-and-play pipe fittings
- Connected to the plant’s SCADA system via wireless sensor nodes
- Commissioned with fluid pressure testing and automated safety trip simulation
The entire process—from arrival to operational status—was completed in under 72 hours, and the plant was back to full production the following Monday.
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
This project reinforced the value of early planning and collaborative customization when it comes to OEM system enhancements.
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
