Learn about sanitary process skids manufacturers in the USA and important things you need to know.

Custom Sanitary Process Skid Systems

This article aims to provide an in-depth understanding of sanitary process skids with attention to manufacturers. Read this article to also learn about sanitary process skid applications, design and fabrication services, and the compliance factors that make them indispensable in contemporary manufacturing.

In industries such as food and beverage, pharmaceuticals, cosmetics (HBA) and chemicals, the need for high-quality, reliable sanitary process equipment and systems is ever-present. Therefore, sanitary process solutions must be engineered to meet stringent standards for reliable efficiency, cleanliness, safety, and durability.

When the need arises to improve our expand production throughput you should consider finding a sanitary process skid manufacturer in the USA instead of getting mired in the tedious process of working with, and coaching, a local building contractor.

Manufacturers In the USA

It is worth stating the obvious; modular skid manufacturing companies are experts at designing, engineering and building quality process solutions that meet customer needs and expectations. Furthermore, a quality manufacturer has the expertise to work closely with you on design consulting, equipment recommendations, and creating an exact-fit solution for your business.

For example, with regard to Arcadia Equipment in Kennesaw, Georgia, you have the benefit of in-house engineering, and turn-key fabrication with UL certified control panels, automation integration, mechanical and equipment installation. Our controls and automation specialists can design, build, and integrate custom process solutions following the latest in UL, CE, GMP, and ISA Practices.

Design and Fabrication Services

The design and fabrication of sanitary process skids require the integration of engineering, material science, mechanical and electrical knowledge. Additionally, all of this culminates in the fabrication by skilled tradesmen. Following, is an overview of the critical stages involved in the skid design and manufacturing processes.

1. Initial Consultation and Requirement Analysis

The design process often begins with discussing specific customer needs and regulatory requirements. Engineers must understand the entire workflow, desired output capacity, and type of products to be processed. This phase often includes:

Flow Diagrams: Engineers develop flow diagrams to visualize how the system will function, identifying necessary components (pumps, valves, tanks, etc.) at this stage.

Material Compatibility: Consideration of the product’s chemical and physiological properties to select appropriate materials.

2. Engineering Design

Once the requirements are clear, detailed engineering design takes place, including:

3D Modeling: Utilizing Computer-Aided Design (CAD) software, engineers create detailed 3D models of the skid systems. These models consider ease of cleaning, maintenance access, and practical operational efficiency.

Simulation and Analysis: The designs undergo hydraulic and thermal evaluations to ensure they meet operational criteria before physical fabrication begins. Finite Element Analysis (FEA) can also be used to understand stress points and ensure the durability of the structure.

3. Fabrication and Assembly

The fabrication process involves several steps:

Material Acquisition: Sourcing high-quality stainless steel and other materials. Certification of materials to ensure they conform to accepted sanitary standards is crucial.

Welding and Fitting: Skilled welders carry out various welding techniques (TIG or orbital welding often preferred) that yield smooth weld joints crucial to cleanability.

Polishing: Post-fabrication polishing enhances surface finishes to reduce roughness and meet specified sanitation standards.

Equipment Integration: Pumps, heat exchangers, and sensors are integrated into the skid based on the design specifications, ensuring they work harmoniously.

4. Testing and Quality Assurance

After fabrication, thorough testing is crucial to ensuring that the sanitarily designed performance standards are met:

Leak Testing: Systems are subjected to hydrostatic or pneumatic tests to ensure there are no leaks in welded joints.

Functionality Testing: The complete skid is tested in line with the operational requirements to guarantee that it performs as intended under actual conditions.

Documentation: Compliance documentation (IQ, OQ, PQ) is crafted to provide evidence that the skid meets client specifications and regulatory requirements.

5. On-Site Installation and Commissioning

Post-fabrication, the sanitary process skid is transported to the client’s facility where:

Installation: Engineers ensure that the skid is installed in compliance with existing operational protocols and safety regulations.

Operator Training: Key personnel receive comprehensive training on the operation, cleaning, and maintenance of the system.

Compliance and Certification

Sanitary process skids must comply with several regulations. Compliance is not only necessary for health and safety but also enhances the reputation of the manufacturers involved. Some key certification standards include:

FDA Regulations: These regulations dictate how food products are processed, packed, and stored to prevent contamination.

USDA Standards: Especially in food-related industries, the USDA mandates strict guidelines regarding hygiene and sanitation.

EHEDG Certification: The European Hygienic Engineering & Design Group provides guidelines and certifications to ensure that equipment meets hygiene standards during design and manufacturing.

What are Sanitary Process Skids?

Sanitary process skids are pre-fabricated systems designed to facilitate the efficient and hygienic processing of fluids, particularly in the food, beverage, pharmaceutical, and biotechnology industries. They encompass an assembly of equipment mounted on a skid or frame, which can support various functions such as pumping, mixing, heating, and cooling. Built compliant with industry standards such as the FDA, USDA, and EHEDG, these skids incorporate materials and components that are easy to clean and sterilize, mitigating the risks of contamination.

What Are Key Features of Sanitary Skids

Material Selection: Sanitary skids predominantly utilize materials like stainless steel (commonly 304L or 316L), which resist corrosion and support low bacteria adhesion. The selection of non-reactive materials is crucial to ensure the integrity of the processed products.

Surface Finish: These skids are characterized by ultra-smooth surface finishes which reduce surface crevices where contaminants may hide. This finish eases the cleaning process, allowing for quick and effective sanitation procedures.

Design: Sanitary process skids are designed to prevent the entrapment of contaminants. They usually feature rounded edges and seamless constructions to minimize cleaning challenges.

Modularity: Skids can be scaled, modified, or updated without extensive downtime due to their modular design. This feature is advantageous for companies seeking flexibility in their production capabilities.

Why Use Modular Skid Systems?

Modular process skids offer several benefits including: reduced costs due to controlled fabrication environments, faster project completion times, improved quality control, increased safety through pre-testing, flexibility in location, portability, and easier installation compared to traditional systems, all while minimizing labor costs and space requirements.

Key Benefits for Industrial Processing Companies

Cost-Effective Expansion: Fabrication and manufacturing in cities such as Atlanta offers lower labor costs than conventional construction in many other parts of the USA.

Minimize Facility Disruption: Off-site fabrication reduces on-site disruptions to basic prep and quick setup upon delivery.

Mitigate On-Site Construction Safety Risks : Minimizing on-site construction means less safety risks for employees in the destination facility.

Portability: Modular skids can be relocated to accommodate future plant layouts changes, and minimize costly down time. Modular skids can also be easily relocated to other facilities.

Quality Control: Fabrication done in a manufacturing facility has the advantage of continual direct inspection by shop managers, designers, and engineers.

Manufacturing Consistency: Working with a single skid manufacturer assures consistent design and fabrication quality when there is a need for multiple skids to be built.

Applications of Sanitary Process Skids

1. Food and Beverage Industry

The food and beverage industry has rigorous hygiene standards due to the direct impact of contamination on consumer health. Applications of sanitary process skids include:

CIP Systems (Clean-In-Place): Sanitary skids are often configured for CIP systems that allow for efficient cleaning without disassembling equipment. These systems utilize high-pressure pumps to circulate cleaning solutions, ensuring complete removal of residues.

2. Pharmaceuticals

In the pharmaceutical industry, where the purity of materials is a prerequisite, sanitary process skids are essential for:

Material Preparation: Skids support the mixing and blending of active ingredients in compliance with Good Manufacturing Practices (GMP).

Bioreactors: In biopharmaceutical applications, skids accommodate the intricate controls required for cell culture processes, which must be kept sterile to avoid product contamination.

Filling and Packaging: Sanitary skids provide the necessary framework for sterile filling operations, such as vials and syringes, ensuring the integrity of the final product.

3. Cosmetics and HBA Products

Cosmetics and HBA Products: Modular sanitary skids streamline the cosmetics manufacturing process by consolidating equipment and optimizing workflows for increased efficiency and product quality consistently.

4. Chemicals Manufacturing

Chemical Industries: Modular process skids simplify chemical manufacturing operations, offering scalable, efficient, and cost-effective solutions for diverse production requirements and environments.

5. Biotechnology

Sanitary process skids play a crucial role in biotechnological operations by providing clean environments for:

Cell Culturing: Skid-mounted bioreactors facilitate controlled environments for effective cell growth while adhering to strict sanitary regulations.


Summary and Key Takeaways

In summary, utilizing a modular approach offers many compelling advantages over on-site construction. Fabrication done in a controlled environment is the ideal way to get the high standards required in many industries. This is especially true for the hygienic needs within food and beverage, pharmaceutical, cosmetic (HBA), and chemical sectors.

Finally, from precise engineering design to robust fabrication with stringent compliance standards, the effectiveness of modular systems ensures safety, efficiency, and product integrity.


Arcadia Equipment is a leading modular process skid manufacturer in the USA. The company provides expert consulting, engineering, design, and fabrication including UL certified electrical panels. For more information, call 770-509-1470.

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