From concept through implementation, we engineer value for industrial processes

Salas O’Brien is a multi-disciplinary engineering and architecture firm, dedicated to finding the right solutions to fit your needs. We are problem solvers, who care about improving your operations, keeping you current with industry trends and regulations, and consistently delivering the quality solutions you’ve come to know and expect.

We use proven methods to execute our projects, while maintaining flexibility and adapting to our clients’ needs and preferences. We work hand-in-hand with our clients to understand their project goals, as we know each project has different parameters defining success.

What we can offer

From initial consultation to full specification and construction facilitation, we offer a complete array of services, including the development of advanced and often groundbreaking solutions when conventional approaches can’t deliver quality results.

Feasibility studies and preliminary engineering

Salas O’Brien examines the technical, economic, and logistical factors to determine if a project is achievable. We also provide the initial phase of engineering where basic design decisions are made, and early calculations and analysis are performed to determine the feasibility of a project.

Process engineering

Salas O’Brien offers comprehensive process engineering services tailored to meet the dynamic needs of the manufacturing and industrial sectors. Our expertise encompasses a wide range of services:

  • Process evaluations and improvements: We conduct thorough process evaluations, scale-up strategies, and implement improvements and debottlenecking techniques to enhance efficiency and productivity.
  • Feasibility and preliminary engineering: Our team specializes in conducting detailed feasibility studies and preliminary engineering to ensure your projects are viable and optimally designed from the outset.
  • Advanced imaging techniques: Utilizing state-of-the-art 3D imaging and laser scanning technologies, we create accurate representations of your facilities, aiding in precise planning and design.
  • Detailed design and documentation: We provide detailed design services, including the creation of Process and Instrumentation Diagrams (P&ID), ensuring clarity and precision in every project phase.
  • Process utility systems: Our expertise extends to designing and optimizing process utility systems, ensuring they are robust, efficient, and meet your specific requirements.
  • Equipment selection and specification: We assist in selecting and specifying the right equipment, aligning with your process needs and industry standards.
  • 2D/3D implementation planning: Our team develops comprehensive 2D and 3D implementation plans, ensuring seamless integration and execution of your projects.
  • Layout design and analysis: We offer equipment and piping layout design services, including thermal pipe analysis, to optimize your operational space and process flow.
  • Competitive bidding and supervision: Our approach includes managing competitive bidding processes and providing diligent site supervision to ensure quality and cost-effectiveness.
  • Start-up and commissioning: From start-up assistance to ongoing commissioning, we ensure your operations kick off smoothly and maintain optimal performance.

Our commitment to excellence in process engineering makes us a trusted partner for your manufacturing and industrial projects.

Simulation & process modeling

Salas O’Brien specializes in advanced simulation and process modeling, utilizing the concept of digital twins to offer precise, real-time insights into manufacturing processes. Our models provide a platform for detailed simulation and analysis. This technology enables us to model complex processes accurately, identify inefficiencies, and predict system performance under various operational scenarios.

We create digital twins as dynamic tools that evolve in parallel to your physical systems, facilitating real-time monitoring and predictive maintenance. This capability is essential for reducing downtime and optimizing productivity. We tailor our simulation and process modeling solutions to meet the specific needs of each project, ensuring that the digital twins serve as a valuable tool for informed decision-making and operational improvement.

Packaging systems

Salas O’Brien provides comprehensive services for packaging systems, designed to enhance efficiency and reliability in your operations. Our approach is methodical and data-driven, ensuring that every aspect of your packaging line is optimized for peak performance.

  • Packaging line audit: We begin with a thorough audit of your existing packaging lines, identifying areas for improvement and ensuring that every component meets the highest standards of efficiency and quality.
  • Feasibility studies and preliminary engineering: Our team conducts in-depth feasibility studies and preliminary engineering assessments to determine the viability and optimal design of your packaging systems, ensuring that they align with your operational goals and budgetary constraints.
  • Detailed design and P&ID: Leveraging our expertise in detailed design and Process and Instrumentation Diagrams (P&ID), we create packaging solutions that are both efficient and scalable, tailored to your specific needs.
  • 2D/3D implementation plan: With advanced 2D and 3D planning tools, we lay out a clear and detailed implementation plan, so that the transition to new or upgraded packaging systems is smooth and disruption-free.
  • Competitive bidding process: We manage the competitive bidding process for equipment and services, ensuring you receive the best value without compromising on quality.
  • Site supervision and startup assistance: Our team provides on-site supervision and startup assistance, guaranteeing that the installation and commissioning of your packaging systems are executed flawlessly, with minimal downtime.

Salas O’Brien can help you make your operations efficient, cost-effective, and ready to meet the demands of a dynamic marketplace.

Bulk material handling

Salas O’Brien’s expertise in bulk material handling is centered around delivering robust, efficient, and sustainable solutions. Our services are designed to address the full spectrum of challenges associated with the handling of bulk materials.

  • Systems design and equipment selection: We specialize in the strategic design of bulk material handling systems and the careful selection of equipment. Our designs are tailored to meet your specific operational requirements, ensuring seamless integration and optimal performance.
  • Feasibility studies and preliminary engineering: Our approach begins with comprehensive feasibility studies and preliminary engineering assessments. This critical phase ensures that every aspect of your bulk material handling system is viable, practical, and designed for efficiency.
  • Dust control and mitigation systems: Recognizing the importance of environmental and workplace safety, we implement advanced dust control and mitigation systems. These solutions are essential for maintaining air quality and complying with health and safety regulations.
  • Operations and maintenance improvements and inspection: We focus on enhancing the operations and maintenance of your handling systems. Through detailed inspections and improvement recommendations, we aim to maximize the longevity and reliability of your equipment.
  • Start-up and commissioning: Our team is committed to ensuring a smooth start-up and commissioning process. We provide comprehensive support to ensure that your systems operate as intended right from the onset.
  • Procurement and structural design: We offer full-service procurement assistance and structural design expertise, ensuring that every component of your bulk material handling system is of the highest quality and designed for durability.

Salas O’Brien understands that efficient and reliable bulk material handling is crucial for your operational success. Our tailored solutions are designed to meet the unique challenges of your industry, ensuring that your materials are handled safely, efficiently, and sustainably.

Hygienic design

Salas O’Brien offers comprehensive solutions that prioritize cleanliness, safety, and efficiency. Our facility designs are meticulously crafted, encompassing walls, ceilings, floors, and doors, all tailored to meet stringent hygienic standards. We specialize in creating environments that adhere to strict standards, ensuring optimal air quality and temperature control. Our team is adept at addressing Environmental Product Control requirements and implementing systems that minimize contamination risks and enhance product safety.

Our expertise extends to the design and integration of Clean Utilities, including steam, water, and compressed air systems. We focus on advanced Water Systems, utilizing technologies like reverse osmosis (RO) and deionization to ensure the highest purity levels. Our solutions include clean-in-place (CIP) & sanitize-in-place (SIP) systems, as well as clean-out of-place (COP) & sanitize-out of-place (SOP) systems, facilitating efficient and effective cleaning processes. We also provide comprehensive cleaning validation services to confirm that cleaning protocols meet all required standards.

Beyond these core elements, our services encompass a broad range of systems critical to hygienic operations. We design and implement advanced cooling towers and heat transfer fluid systems, as well as compressed air & nitrogen systems. Our electrical systems design and lighting solutions are tailored to meet the specific needs of hygienic environments. We also specialize in instrumentation design, including the selection and placement of instruments for pressure, flow, level, and temperature monitoring, ensuring all connections meet IPK69 Standards. Additionally, we integrate motors, industrial computers & monitors (HMI’s), and robotic systems to enhance operational efficiency and precision in hygienic settings.

Process safety & risk management

Salas O’Brien is dedicated to ensuring the highest safety and compliance standards in your operations. Our approach is rooted in a deep understanding of the complexities and risks inherent in industrial processes, and we are committed to identifying and mitigating these risks effectively. We offer a comprehensive suite of services including:

  • Hazardous area classification
  • Ergonomic & safety equipment
  • Building & fire code compliance
  • P&ID development & verification
  • Relief system design & sizing
  • Design codes & standards verification
  • Vessel MAP / MAV calculations
  • Facility siting evaluations
  • Finite element analysis
  • Layer of protection analysis
  • Safety Integrity Level Verification
  • Dust Hazard Analysis (DHA)
  • Process Hazard Analysis (PHA)
  • cGMP regulatory compliance
    • Development and Assistance in Implementing full PSM Programs or Specific Elements
    • Process Hazard Analysis Leader and Scribe
    • PSM Program Auditing

Validation & commissioning

Salas O’Brien specializes in delivering comprehensive validation and commissioning services that ensure your systems and processes meet all necessary standards and perform optimally. We offer a comprehensive suite of services including:

  • Gap analysis
  • Risk & impact assessment
  • Validation Master Plans (VMP)
  • Design Qualifications (DQ)
  • GAMP Specifications (URS/FS/DS)
  • Qualification Protocols (IQ/OQ/PQ/CV)
  • Commissioning Plans (CP)
  • TOP requirements
  • Factory & site acceptance tests
  • cGMP Construction Segregation Plans (CSP)
  • cGMP Compliance Audits