Capacity Expansion Install

Keen Project Solutions served as construction partner for a high‑risk, large‑scale brownfield installation at ADM’s Frankfort soybean crush facility. Executed within an active agricultural processing environment, the project expanded receiving and material handling capacity while maintaining full operations — requiring careful coordination, early procurement and innovative construction sequencing to meet harvest‑driven demands.

Working closely with ADM and the engineer of record, Keen supported design development, constructability reviews and execution planning to validate the final concept and protect schedule certainty. The project modernized aging infrastructure through extensive material handling, structural, civil and electrical upgrades designed to significantly increase throughput.

A critical element of the work involved replacing and relocating major receiving equipment at the center of the operating plant. Keen demolished an existing production office and constructed a deep receiving and boot pit measuring approximately 60 feet by 70 feet and 35 feet deep. The excavation was surrounded by active process systems, utilities and critical structures and was completed without interrupting plant operations.

Overall improvements included approximately 1,400 linear feet of new belt and drag conveyors, 500 vertical feet of bucket elevators, 600 vertical feet of towers and 800 linear feet of catwalks. Two new CMU motor control center buildings were constructed to relocate electrical infrastructure outside the grain elevator. One building also included personnel support spaces, hexane monitoring and dewatering alarms to enhance safety and operational reliability.

Additional scope included installation of a high‑capacity soybean receiving system, upgrades to the rail‑served soybean meal receiving system, expanded receiving pits, new pre‑engineered metal buildings for receiving operations — and a dust collection system integrated with existing and new equipment, including explosion isolation protection. Keen also implemented a 3D bin inventory mapping system across two one‑million‑bushel bins to improve inventory visibility and data accuracy.