Seamless Integration at Utah Flour Mill Project

Interstates recently played a critical role in the successful design, construction, and automation of electrical systems for a new flour mill in Richmond, UT. This greenfield facility was constructed through Interstates’ Integrated Project Delivery (IPD) model and is designed to supply a major national snack food producer with high-quality flour. The project presented several challenges, including unique integration requirements with an adjacent food processing facility and extensive underground electrical work. Through collaborative planning, innovative solutions, and strong project execution, Interstates helped deliver a highly efficient and well-integrated mill.

Overcoming Challenges with Precision

Unlike traditional flour mills, which are typically constructed using concrete slip-form methods, this facility was built with an all-steel structure. This innovative approach significantly reduced project delivery time, allowing for faster commissioning and earlier production startup. Additionally, by leveraging building information modeling (BIM), the team efficiently routed conduits and optimized space utilization, further enhancing construction efficiency and long-term maintainability. 

There was also an extensive underground electrical installation, an uncommon requirement for a flour mill. With roll stands positioned on the first floor, all related electrical conduit had to be precisely stubbed up 76 times. “We had surveyors out multiple times to ensure these were landed in the correct spot, and we leveled all the pipes with a laser,” explains Trevor Turgeon, Site Assistant Project Manager I at Interstates. 

A Strong Partnership for Project Delivery

The expertise and collaboration of Interstates’ power engineers, automation engineers, and construction professionals played a crucial role in keeping this fast-tracked project on schedule. Partnering with Bratney, the project’s general contractor, our team built a foundation of trust that proved invaluable as construction progressed. As our teams worked together—leveraging both Bratney’s and Interstates’ expertise—to ensure the facility was fully operational by February, this trust became especially evident once the building shell was completed.

Under the leadership of Tim Allen, Superintendent at Interstates, the team worked closely with Bratney to coordinate a critical-path mechanical installation schedule that aligned with our system checkout process. The team from Bratney focused on this coordination, ensuring all elements came together despite challenges such as winter weather, holiday schedules, and typical construction constraints. By prioritizing safety, agility, and clear communication, the teams overcame obstacles and delivered a fully functional mill ready to produce and transfer flour to the adjacent facility on time.

Efficiency and Cost-Saving Measures

With strategic planning, Interstates improved efficiency and reduced costs throughout the project. Significant savings came from embedding conduit within the concrete slab before the deck was poured. “This saved us from being limited on space to hang our supports and resulted in substantial labor cost savings,” Turgeon says. Planning out work around high-traffic areas was another priority. “Coordination is key,” Allen says. “The steel erectors and Bratney’s millwrights were very easy to work with, which made things run smoothly.” 

Standard specifications established during this project will serve as a template for future flour mill designs, helping other projects run more smoothly. For example, the decision to avoid strut and all-thread in the mill process area improves cleanliness and maintenance efficiency.

Smooth Startup Delivered

Reflecting on leadership strategies that helped keep the project on schedule, Allen credits teamwork and morale-building efforts. “Prefab helped a lot—it took some of the work out of the field. Having the right people and keeping morale high made a big difference,” he says.

With the project recently completed, Turgeon says early feedback has been positive: “For the receiving area, which includes 50 motors and 114 devices, the general contractor said it was the smoothest startup he has ever experienced.” Ultimately, this project is another great example of Interstates’ commitment to delivering high-quality, integrated electrical solutions.