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Plant Layout & Process Flow Design Services

Hixson delivers integrated plant layout and process flow design services that help manufacturers improve throughput, safety, and space utilization. From early planning through equipment layout, utility coordination, and startup support, our team creates practical designs that reduce risk, support compliance, and align operations, engineering, and capital goals under one experienced partner.

Engineers reviewing plant layout and process flow plans

Our Plant Layout & Process Flow Design Services

Integrated planning, engineering, and optimization services for efficient, scalable, and compliant manufacturing environments.

Master Planning

Develop long-range facility strategies that align production goals, expansion needs, site constraints, and capital priorities into a practical roadmap for future growth.

Process Engineering

Translate manufacturing requirements into block flow diagrams, process flow diagrams, equipment layouts, utility needs, and detailed engineering deliverables that support efficient operations.

Controls Integration

Coordinate automation, network design, PLC and HMI requirements, and commissioning support so plant layouts and process systems work together seamlessly.

Strategic Consulting

Evaluate facility performance, operational goals, and future-state requirements to guide layout decisions that reduce risk and improve project outcomes.

Site Selection

Assess potential sites for operational fit, infrastructure readiness, and long-term scalability before layout and process design decisions are finalized.

EH&S Planning

Incorporate environmental, health, and safety considerations early so layouts support permitting, compliance, safe movement, and efficient production workflows.

Plant design team reviewing process steps

Our Plant Design Process

Assess Goals and Constraints

We begin by reviewing production targets, product mix, staffing, utilities, safety requirements, and expansion plans. This discovery phase aligns business objectives with practical facility and process design criteria.

Map Process Flow Requirements

Develop Equipment Layout Concepts

Coordinate Multidisciplinary Design

Support Implementation and Startup

Trusted By Industry

Project Results

See how integrated planning and engineering help complex facilities move from concept to successful operation.

"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?

Clients choose Hixson for integrated expertise, long-term experience, and practical project leadership.

Integrated Team

Twenty in-house disciplines streamline coordination from planning through engineering, reducing handoff delays and project risk.

Deep Experience

Since 1948, Hixson has built specialized facility knowledge for complex manufacturing and technical environments.

Project Leadership

Proven project management methods keep layout, process, budget, and implementation priorities aligned throughout delivery.

Trusted Culture

Great Place to Work certified with long-tenured teams that bring consistency and collaborative client support.

Meet The Hixson Team

Experienced leaders guiding complex facility projects.

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.

Steve Guyer P.E. professional headshot

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 the plant layout design process?

The plant layout design process typically starts with understanding production goals, product flow, staffing, utilities, safety requirements, and future growth plans. From there, engineers develop block flow and process flow diagrams, create equipment and space layouts, coordinate building and utility systems, and refine the design through multidisciplinary review. The process often continues through specifications, procurement support, commissioning, and startup.

What are the 4 types of facility layout?

What is the difference between plant layout and process layout?

Why is process flow design important in manufacturing facilities?

What deliverables are included in plant layout and process flow design services?

Can plant layout design help with future expansion planning?

How do automation and controls affect plant layout decisions?

Which industries benefit most from plant layout and process flow design?

Still Have Questions About Layout Design?

Talk with our team about planning, flow, and facility requirements.

Certified & Recognized

Awards and Recognition

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Great Place to Work

Certified workplace culture and team excellence.

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Rising Giants 178

Interior Design magazine industry recognition.

Industry recognition certification badge

Sector Recognition

Recognized across core industry sectors.

Plan a Smarter, More Efficient Facility

Share your project goals, facility challenges, or expansion plans, and our team will help outline the right next steps.

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.