VAA was retained by a design-build contractor to provide design and engineering services necessary for expansion of Big Gain's existing feed mill located in Mankato, MN.  The design included adding a second line to almost double production to 250,000 tpy.  New structural components were tied into the existing infrastructure including warehousing, capability to receive, manufacture and load out between the two plants in order to operate as one.

The plant's unique manufacturing of a full line of feeds for swine, dairy, beef and specialty feeding required careful separation of ingredients.  Components of the plant include new truck receiving, ingredient storage, batching, mixing, grinding, pelleting, finish feed/load out bins, and micro ingredient system, including minor ingredient storage in overhead bulk bins.

The flexibilities of the completed project will enable ingredients and grain to be received in the existing mill and processed in the new mill and vice versa.  Additionally, if there are maintenance issues, or either facility needs to be shut down unexpectedly, the plant can maintain partial manufacturing capacity.  The mills are able to run independently or simultaneously and transfer between the two acting as one plant.

The existing site and placement of the new mill were extremely tight requiring creative design and construction solutions.  The basement of the new plant was dug inside of the existing mill warehouse, while maintaining operations throughout construction.  The special construction technique utilized was to remove the roof of the adjacent warehouse, excavate the new basement, drive soil nails, install reinforcing and spray shot concrete to construct the new basement walls.  Careful preparation was taken to separate areas to allow for normal operations to continue.

Planning, creative design and knowledgeable experience by the design-build team, provided Big Gain creative solutions that resulted in a successful project.