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Functional Food Pilot Plant Facility Design & Engineering

Bring functional food concepts from bench trials to scalable pilot production with Hixson’s integrated architecture, process engineering, sanitary design, and controls expertise. Backed by more than 75 years in Food & Beverage projects, we help teams validate formulations, improve manufacturability, and plan compliant, flexible facilities for nutraceuticals, beverages, plant-based products, and emerging wellness brands nationwide.

Functional food pilot plant processing suite

Our Functional Food Pilot Plant Facility Design & Engineering Services

Integrated design and engineering services for pilot-scale functional food, nutraceutical, beverage, and process development facilities.

Pilot Lab Design

Design R&D, QA/QC, analytical, and pilot plant environments that support product development, testing, equipment trials, and safe collaboration between laboratory, office, and production functions.

Process Engineering

Translate functional food formulations into practical manufacturing concepts through flow diagrams, equipment layouts, utility requirements, P&IDs, HAZOP support, procurement assistance, and startup planning.

Nutraceutical Facilities

Plan pilot and production spaces for powders, capsules, gummies, functional beverages, protein supplements, and dietary products with cGMP, NSF, SQF, and sanitary design considerations.

Sanitary Design

Integrate hygienic zoning, cleanable finishes, slope-to-drain floors, sanitary piping, allergen segregation, CIP-ability reviews, and FDA, USDA, SQF, 3-A, BISSC, AMI, and EHEDG principles.

Controls & Automation

Develop pilot-scale control strategies for batching, blending, thermal processing, CIP, packaging integration, utilities, PLC programming, HMI development, FAT/SAT, and commissioning.

Packaging Engineering

Design flexible filling, bottling, pouching, canning, check weighing, metal detection, conveyance, labeling, cartoning, case packing, and pilot packaging systems for varied product formats.

Engineers reviewing pilot plant process drawings

Our Pilot Plant Design Process

Define Product and Facility Objectives

We begin by clarifying product formats, pilot objectives, throughput targets, regulatory needs, operational constraints, and future scale-up goals so the facility concept supports both experimentation and manufacturable outcomes.

Map Processes and Critical Flows

Engineer Integrated Facility Systems

Support Procurement and Construction Documents

Assist Startup and Commissioning

Trusted By Leaders

Proven Project Experience

Hixson has supported major food, beverage, science, and workplace clients with complex facility projects.

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis
The Hixson Difference

Why Choose Hixson?

Choose a partner with deep technical depth, integrated delivery, and proven Food & Beverage expertise.

75+ Years

Founded in 1948, Hixson brings decades of specialized Food & Beverage facility experience.

Integrated Disciplines

Twenty in-house technical disciplines coordinate architecture, process, engineering, controls, and project delivery.

Sector Expertise

Specialized teams understand nutraceuticals, beverages, labs, plant-based proteins, and regulated manufacturing.

Risk Reduction

Proven methodologies, performance tools, and experienced leaders help reduce project uncertainty.

Meet Hixson’s Experts

Experienced leaders guide complex facility design and engineering work.

John Brockmeier P.E. professional headshot

John Brockmeier P.E.

Manager, Plumbing Systems & Fire Protection Engineering

John oversees the department responsible for the design and engineering of plumbing systems and fire protection engineering for a variety of project types, including new construction, building utility upgrades, utility capacity analyses, and process line additions. John and his team work with a range of systems, including domestic water, process water, hot water production, direct contact water heaters, high pressure/rinse water, compressed air, natural gas, sanitary drainage, process drainage, central sanitation systems, fire pumps, and fire sprinkler systems.

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Craig Cheevers

Manager, Controls & Automation Engineering

As the Manager of Hixson's Controls & Automation department, Craig guides the team responsible for designing, implementing, and commissioning advanced control systems and automation solutions. His responsibilities include overseeing the development of automation strategies that streamline manufacturing processes, enhance operational efficiency, and ensure seamless integration of new and existing systems.

Warren Green P.E. professional headshot

Warren Green, P.E.

Manager, Process Engineering

Warren leads the team providing processing design services, process optimization studies, and process commissioning and FAT, SAT, and IQ activities. He advises on waste, energy, and GHG emissions reductions, and conducts safety and dust evaluations, including PSM/HAZOP. His expertise spans all food and beverage sectors including fluid, dried and cultured dairy products, processed meat, flavors, and prepared foods. Warren is also on the IDFA Food Safety Committee and actively participates in the 3A, SSI steering committee, and work groups.

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Steve Guyer, P.E.

Manager, Civil Engineering

In his role as Manager of Civil Engineering, Steve leads the team responsible for the planning, design, and engineering of roads, stormwater hydraulics and modeling, and onsite utilities. On project work, Steve is responsible for civil site project design, specifications, technical design, and project coordination with the client, government regulatory bodies, outside consultants, and contractors. As a senior staff member with our firm, Steve also serves as a mentor to newer associates.

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Chris Jarc, P.E., PMP, LEED AP

Vice President & Director, Project Management Services

Chris, a Hixson officer and member of the Board of Directors, oversees Hixson’s Project Management, Cost Estimating, and Construction Administration departments. Chris also serves in a project management role, leading teams consisting of representatives from the client, Hixson, contractors, and vendors to effective project completion. Chris assumes overall responsibility for development of project delivery strategies, coordination of all Hixson disciplines, and facilitating effective communication and management to focus resources on delivering high-quality projects on time and within budget.

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Dave Klenk

Manager, Mechanical Engineering

Dave brings more than three decades of experience to his role as the Manager of Hixson’s Mechanical Engineering Department. His work has included the design and project management of new facilities, as well as modification of existing facilities for high technology and food processing industries. At a corporate level, Dave is a member of Hixson’s Dairy and Beverage Industry team, which works to continuously improve the value Hixson offers to the dairy industry through development of our knowledge base, services and capabilities.

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Kyle McAllister

Manager, Electrical Engineering

Kyle serves as the Manager of Hixson’s Electrical Engineering department. In this role, he oversees the team responsible for the creation and delivery of electrical designs. This includes the design of high, medium, and low voltage power distribution, lighting, telecommunications, and fire alarm systems. Kyle brings more than 15 years of experience in electrical consulting and design to his role. Areas in which Kyle specializes include electrically hazardous area classification, high- and medium-voltage power distribution, protective relaying, arc flash studies, harmonics analysis, cogeneration design, emergency systems design, and complex laboratory designs.

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Scott McGlamery, P.E.

Senior Vice President, and Director, Mechanical & Electrical Engineering

Scott, an officer of the firm, leads the teams responsible for mechanical and electrical project tasks and design, specifications, technical content, consultation during equipment selection and installation and systems start-up assistance. In addition, Scott also serves as the Quality Assurance Manager, overseeing the firm’s commitment to quality. Over Scott’s more than three decades of experience, he has worked on greenfield, brownfield, and renovation projects for food & beverage plants in all sectors, labs, pharma & biotech facilities, and workplace projects.

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Scott Wever

Manager, Manufacturing Engineering

In his role as Manager of Hixson’s Manufacturing Engineering department, Scott leads the team responsible for project consulting and coordination between client, vendor, and internal disciplines within Hixson for overall manufacturing processes, functionality, equipment, and layouts. These team members develop process flow diagrams, equipment lists, and preliminary utility requirements, as well as develop equipment layouts that range from high level master planning to detailed construction documents. In addition to this role, Scott is a member of Hixson’s Meat Industry advisory team, focusing on technologies related to the meat and plant protein industry.

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Derek Wojcikowski

Director of Architecture

Derek is the Director of Hixson’s Architecture department. In this role, Derek leads the teams who design projects for our Food & Beverage, Pharma & Biotech, Laboratory, and Workplace clients. Previously, Derek served as the Manager of Hixson’s Process Layout department, where he directed the team that plays a critical coordination role in the overall development of process models and the 3D equipment model management process. Prior to these management roles, Derek, who began his career with Hixson in 2008, served as a Project Architect.

Frequently Asked Questions

What is a pilot plant in the food industry?

A pilot plant in the food industry is a smaller-scale processing facility used to test formulations, equipment, process conditions, sanitation approaches, packaging formats, and production workflows before full commercial investment. It helps manufacturers validate product quality, throughput, regulatory requirements, utilities, controls, and operator procedures in a realistic manufacturing environment.

What is the purpose of a pilot plant?

What services are included in functional food pilot plant design?

How does Hixson support scale-up from pilot plant to production?

What types of functional food products can a pilot plant support?

How are food safety and sanitary design handled?

Can an existing space be converted into a pilot plant?

When should we involve an engineering team in pilot plant planning?

Still Have Pilot Plant Questions?

Connect with Hixson’s experts to discuss your facility goals.

Certified & Recognized

Awards and Recognition

Great Place to Work certification logo

Great Place to Work

Certified organization with strong associate culture.

Interior Design Rising Giants recognition logo

Rising Giants

Ranked No. 178 by Interior Design.

Top firm industry recognition logo

Top Sector Firm

Recognized in core specialized markets.

Plan a Smarter Functional Food Pilot Plant

Share your product goals, facility needs, and project timeline. Hixson will help you identify the right next steps for pilot plant design, engineering, and scale-up planning.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 513-241-1230. You can also send us a quick email at info@hixson-inc.com.