VAA led the expansion of a major malt processing facility for the oldest malting company in the Western United States, increasing the plant’s process capacity by 120% through an accelerated design-build approach.

The project presented Structural Engineer (Hybrid) Minneapolis, MN Hybrid significant challenges, including a limited site footprint, sensitive processing equipment, and aggressive project timelines. VAA’s multidisciplinary engineering team developed innovative solutions that integrated new process infrastructure while accommodating strict space and utility constraints.

The expansion included the design of a new steeping building, four germination vessels, a kiln vessel, transfer systems, utility buildings, and heavy-duty transfer conveyor bridges. As part of the fast-tracked delivery strategy, VAA completed construction Electrical Designer (Hybrid/Remote) Minneapolis, MN Hybrid plans four months ahead of construction and continued providing engineering drawings throughout the year-long build to support seamless project execution.

The completed expansion substantially increased production capacity, improved process efficiency, and modernized the facility while maintaining reliable operations.

Malt Production Facility Expansion

VAA provided engineering design and facility layout services for the expansion of two malt production facilities, increasing each plant’s production Structural Designer (Hybrid/Remote) Minneapolis, MN Hybrid capacity to 25,000 metric tons of malt per year while maximizing the use of existing infrastructure.

The project required careful planning due to limited site footprints, the placement of existing structures, and the need to maintain efficient production workflows. VAA successfully integrated and repurposed existing buildings into the new facility layouts, minimizing construction costs while optimizing operational efficiency.

The expansion included the design of grain receiving systems, malt production processes, storage facilities, loadout systems, roasting Electrical Engineer (Hybrid) Minneapolis, MN Hybrid operations, bagging lines, and tote filling stations. Because both facilities were located within a floodplain, VAA ensured all designs complied with FEMA floodplain regulations and incorporated the necessary flood mitigation requirements into the project.

The completed expansions enhanced production capacity, improved facility efficiency, and created flexible, code-compliant operations capable of supporting long-term growth.