At Bassett Mechanical, we pride ourselves on building strong partnerships with our customers and delivering solutions uniquely tailored to their needs. Our recent collaboration with Ornua, a global leader in dairy products, is a testament to this commitment. By designing and constructing a custom modular engine room, we provided an innovative solution that addressed Ornua’s specific operational requirements and overcame unique site challenges to enhance their efficiency and performance.

The Project

Ornua needed to replace its aging engine room, which was out of code compliance and featured equipment nearing the end of its lifecycle. The confined site posed additional challenges, including tight space restrictions and the need to fit the system within an existing footprint while maintaining efficient installation practices.

Previously, we had modified shipping containers to meet customers’ engine room needs. These prefabricated units proved cost-effective, customizable, and scalable—ideal for facilities requiring efficient and reliable refrigeration systems. For Ornua, however, we developed a solution with even greater flexibility.

“Instead of modifying a shipping container, we designed a steel frame from scratch. This gave us more control and flexibility, and we could even leave the roof off to drop in large compressors with a crane before securing the roof in place,” said Ryan Y., Refrigeration Manager.

Our Innovative Approach

Custom Steel Frame Design

Using our structural cutter, we fabricated a steel frame, fully customizable in size, width, and height to fit the site’s restrictions. The container was 36’ L x 12’ W x 12’ H with an overall weight of 47,000 pounds. The frame was pre-welded, painted, and insulated with Insulated Metal Panels (IMPs) in-house, ensuring quality control at every stage. This approach minimized fieldwork, as most assembly was completed in our shop, leaving only minimal tie-ins for ammonia, water, and electrical on-site.

In addition, we opted for a larger container design, providing more workspace for service technicians and ample room for multiple trades to work simultaneously.

Efficient Installation

The installation process was streamlined with a carefully planned sequence. The design featured a removable roof, enabling cranes to lift and place large compressors and equipment inside, eliminating the challenges of maneuvering equipment through narrow container doors. Once the equipment was installed, the roof was secured, simplifying on-site installation and minimizing downtime.

We also pre-installed steel struts for mounting panels, louvers, and exhaust fans. Openings for components were strategically planned and fabricated in advance, further reducing shop and fieldwork.

3D Modeling and Prefabrication

Our Metal Fabrication team used advanced 3D modeling to design the system, ensuring precision and flexibility. This process allowed for adjustments before cutting metal, reducing waste and controlling costs. Prefabrication included pre-wiring electrical components and assembling pipe racks with threaded couplings, streamlining on-site connections, and reducing labor time.

“A huge benefit of 3D modeling is reviewing the layout with the customer before any steel is cut. That way, the customer knows exactly what they are getting,” noted Ryan Y.

Key Benefits for Ornua

• Cost Savings: The modular design consolidated the replacement of outdated vessels, condensers, and piping into a single project, avoiding piecemeal upgrade costs.
• Enhanced Compliance: The new engine room meets current code standards, eliminating the challenges of retrofitting an old structure.
• Optimized Space and Flexibility: Custom dimensions perfectly fit the existing pad and provide a more spacious layout than standard container modifications.
• Seamless Transition: The system was tied into the existing refrigeration network over a three-day weekend, minimizing operational disruption.

Collaborative Success

This project was a true team effort. Everyone, from design engineers and manufacturing teams to project management and field operations, played a crucial role in delivering a successful outcome. We exceeded expectations by involving Ornua in design discussions and leveraging our internal expertise.

Looking Ahead

Bassett Mechanical’s custom modular engine rooms offer an ideal solution for food and beverage facilities facing space constraints, aging infrastructure, or the need for future growth. Our flexible designs and turnkey approach ensure efficient, compliant, and scalable refrigeration systems.

Contact Us

Learn how we can bring innovative refrigeration solutions to your facility.

Check out a 360-degree view of the project before it heads out to the job site!