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Automated crane bay inside the Plant 19 facility

4.3 million tons a year.One operator.

Plant 19 was designed around a different question: what would a material handling environment look like if flow, equipment, space, safety, and production were considered together from day one?

  • Throughput

    4.3M

    tons annually

  • Operation

    1 operator

    at full power

  • Coordination

    2 automated cranes

    + transfer cars

  • Sustainability

    LEED certified

    facility

01The opportunity

The opportunity was a blank sheet of paper.

Traditional facilities are built around the building first, and the operation is forced to adapt later.

Plant 19 started with the operation and designed everything else around it.

Traditional greenfield thinking

  1. Building
  2. Aisles
  3. Equipment
  4. Storage
  5. People
  6. Workflows
vs.

CareGo greenfield thinking

  1. Production requirements
  2. Material flow
  3. Safety separation
  4. Storage strategy
  5. Equipment coordination
  6. Facility layout

Design the building around the operation, not the operation around the building.

02Throughput & operating leverage

Designed for throughput at scale.

Traditional operation

  • Multiple people.
  • Manual coordination.
  • More touches.
  • More waiting.
4.3Mtons annually

Plant 19 environment

  • One operator.
  • Coordinated environment.
  • Continuous flow.

One operator oversees the environment. The system coordinates the movement.

03Safety by design

Safety was designed into the environment before it existed.

Isometric view of organized coil storage with clear lanes
  • Less human interaction
  • Coordinated equipment
  • Controlled movement
  • Safer operating environment

People stay out of the path. The environment handles the work.

04Coordinated equipment / how it works

Two cranes. Transfer cars. One environment.

  1. Crane 1

    Receive

  2. Transfer car

    Move

  3. Crane 2

    Store / retrieve

  4. Bays

    Organized storage

CareGo intelligence coordinates the whole flow.

05What Plant 19 proved

  • 4.3M

    tons annually

  • 1 operator

    at full power

  • Extremely little

    human interaction

  • LEED certified

    facility

  • Purpose built

    around flow from day one

Plant 19 became the benchmark for CareGo's future.

06How CareGo did it

  • Greenfield facility design

    Greenfield facility design

  • TELIA / coordinated control

    TELIA / coordinated control

  • Two automated cranes

    Two automated cranes

  • Automated transfer cars

    Automated transfer cars

  • Facility & energy management

    Facility & energy management

07Different roles. One designed advantage.

  • Owner

    A facility that delivers maximum long term value with lower risk and stronger performance.

  • CEO

    Throughput and reliability engineered into the business model from day one.

  • CFO

    Lower total cost of ownership and sustainable returns through efficiency.

  • VP of Operations

    More consistent flow, fewer interruptions, and higher productivity.

  • Plant Manager

    Safer environment, simpler operation, and confidence in daily execution.

Planning a facility of your own?

Tell us what your operation needs to become and we will design around it.

Contact Us