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.
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.

Integrated design and engineering services for pilot-scale functional food, nutraceutical, beverage, and process development facilities.
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.
Translate functional food formulations into practical manufacturing concepts through flow diagrams, equipment layouts, utility requirements, P&IDs, HAZOP support, procurement assistance, and startup planning.
Plan pilot and production spaces for powders, capsules, gummies, functional beverages, protein supplements, and dietary products with cGMP, NSF, SQF, and sanitary design considerations.
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.
Develop pilot-scale control strategies for batching, blending, thermal processing, CIP, packaging integration, utilities, PLC programming, HMI development, FAT/SAT, and commissioning.
Design flexible filling, bottling, pouching, canning, check weighing, metal detection, conveyance, labeling, cartoning, case packing, and pilot packaging systems for varied product formats.

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.
Hixson has supported major food, beverage, science, and workplace clients with complex facility projects.
Choose a partner with deep technical depth, integrated delivery, and proven Food & Beverage expertise.
Founded in 1948, Hixson brings decades of specialized Food & Beverage facility experience.
Twenty in-house technical disciplines coordinate architecture, process, engineering, controls, and project delivery.
Specialized teams understand nutraceuticals, beverages, labs, plant-based proteins, and regulated manufacturing.
Proven methodologies, performance tools, and experienced leaders help reduce project uncertainty.
Experienced leaders guide complex facility design and engineering work.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.
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.
Connect with Hixson’s experts to discuss your facility goals.
Certified organization with strong associate culture.
Ranked No. 178 by Interior Design.
Recognized in core specialized markets.
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.
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.
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.