Want the right tank for your process? Start with the right information
Successful tank projects begin before you even have that first conversation with the Watson Custom Tanks team.
By definition, every custom tank project is unique. Therefore, every project starts from scratch, and that’s information gathering.
From product flow to agitation needs to material finish, every design detail affects the fabrication process in some way. The more information you can provide at the outset, the easier it becomes to create a solution that meets your goals.
Here’s some key information you can bring to us to help save time, improve accuracy and mitigate miscommunication throughout the design, fabrication and shipping processes.
Identify Industry Standards & Compliance Requirements
Industry standards, e.g., ASME, BPE and UL codes, often directly influence how a tank is designed, fabricated, tested and documented. Because you’re in the industry, you likely know what standards apply to your tanks. Take a moment to write them down before starting your quote request. Not only will this help ensure none are overlooked, but it could also help remind you of any lesser-known requirements.
Identifying these codes early helps avoid redesigns later in the project or, worse, a non-compliant vessel. With that knowledge from the start, engineers and fabricators know what processes, materials and inspections are needed to ensure compliance and a tank that meets your needs. Watson can fabricate tanks that meet ASME, API, UL, Dairy, USDA and BPE standards, among others.
If you're unfamiliar with specific requirements, organizations such as the American Society of Mechanical Engineers (ASME) and 3-A Sanitary Standards provide guidance for many food, beverage, pharmaceutical and industrial applications.
Checklist
Applicable design codes, e.g., ASME, BPE, UL, CRN, 3-A
Inspection requirements
Application- &/or product-specific standards
Regional compliance requirements
Documentation expectations
Define Product & Material Requirements
What goes inside the vessel affects design decisions, too. Product characteristics can influence material selection, interior finishes, cleaning and sanitation requirements, outlet sizes and placement and even the tank’s longevity. Even products that are similar in makeup might be compatible with different materials.
For example, food-grade products, dairy ingredients, beverages, acids, caustics, and abrasive slurries can all have different material compatibility requirements. Some, such as chloride, even react to stainless steel and can accelerate tank degradation. Selecting the wrong material may reduce service life, increase maintenance or create sanitation challenges.
Resources like the Nickel Institute and chemical compatibility databases can help manufacturers better understand how specific products interact with various metals and alloys.
Interior and exterior finishes are more important in some industries than others. In many instances, it’s not the product that affects this aspect, but rather the cleaning process.
Understanding the application helps ensure your custom tank is customized to your needs. Food, beverage, dairy and pharmaceutical processors require smoother interior finishes to mitigate product buildup and improve sanitation. On the other hand, chemical processors don’t have to worry about hygiene so a basic mill finish might work.
By understanding your product’s exact needs, Watson can design a tank that meets them just right, without adding unnecessary features or costs.
Checklist
Product description
Material preference
Interior finish requirements
Exterior finish requirements
Corrosion concerns
Sanitation requirements
Understand Operating Conditions
Understanding operating conditions is one of the most important steps in any custom tank fabrication project and can affect vessel size, wall thickness, nozzle placement, pressure ratings and support structures. Even future growth plans can influence size and configuration decisions.
Sometimes, customers know how much product they produce each day, but not how those numbers translate into vessel capacities. That’s okay. Provide as much operational information as possible, and the Watson engineers can assist you in determining the rest. Watson, like most quality tank fabricators, has engineers who can usually calculate your capacity needs based on your input.
Tank volume calculators can also help estimate capacity requirements before discussing options with your fabrication team.
Checklist
Product volume
Batch size
Production rate
Operating pressure
Operating temperature
Future expectations & growth plans
Determine Heating & Cooling Needs
Temperature control is key information, and it’s more than just “heating” or “cooling” product. Some products require rapid heating and cooling, while others need a consistent temperature with no tolerance. Even how fast you want to heat or cool your product affects the overall design. Depending on the application, temperature control may be achieved through jackets, coils, or other integrated heat-transfer systems. Identifying heating and cooling goals early helps ensure the vessel can achieve the desired process performance.
Once Watson engineers understand how you use temperature, we can discuss which solutions will meet your needs efficiently and safely.
Checklist
Heating requirements
Cooling requirements
Temperature maintenance requirements
Utility medium
Heat transfer pressure requirement
Outline Installation & Footprint Constraints
One often overlooked part of a tank project is how it will fit into the facility. Floor space, ceiling height, access points and utility locations all affect how the tank is fabricated and/or integrated. Some processors tailor their tank dimensions to their existing space. Others make space by removing walls or raising ceilings.
Even if the tank will fit into your facility, its size could affect how it gets there. Larger vessels require special delivery methods, which could affect delivery times. In these cases, field fabrication is a great option. The Watson field service team will travel to the processor’s location and assemble the tank on-site, whether that’s outside or in.
Knowing these limitations at the start avoids surprises during installation.
Checklist
Available footprint
Ceiling height
Door dimensions
Access routes
Utility locations
Installation restrictions
Plan Support Structures & Access
A tank solution is more than just the vessel itself. It comprises a complete support system and access features for safe, efficient and reliable operation. Depending on the application, this may include platforms, ladders or skids, to name a few.
Taking this into consideration early not only ensures you have a safe, accessible tank solution–it helps the team plan out component fabrication so all the pieces come together at the right time.
Checklist
Support system type
Load requirements
Operator access needs
Platform requirements
Ladder or stair requirements
Weighing requirements
Define Mixing, Blending &/or Agitation Requirements
If needed for the product, agitation is one of the most important parts of the tank design discussion. There’s no one-size-fits-all solution that fits every product. Some products require aggressive blending while others just need agitation.
Agitation systems come in a variety of styles, including top-mounted, bottom-mounted, side-entry and high-shear. Each has its own benefits for different products and processes. For example, mayonnaise and other emulsified products often need high-shear mixing to create a stable product, whereas wastewater agitation may focus on preventing sediment settling.
Industry is key, too. Food and beverage processors, chemical manufacturers, personal care producers and pharmaceutical companies all have drastically different agitation requirements, even though they might have similar-sized tanks.
The most important information isn’t what type of agitator is needed–it’s what you’re trying to accomplish. Are you simply keeping solids suspended to prevent settling? Or, are you blending multiple ingredients? Creating emulsions? Processing highly viscous products? How fast do you want to blend product? Ideal product temperature even plays a part in designing the right system.
The more information about your product goals, the easier it is to integrate the right agitation system for your success.
Checklist
Agitation requirements
Product characteristics
Processing objectives
Batch or continuous operation
Existing agitator specifications
Emulsification requirements
Needed operating speeds
Preferred agitator location
Share Testing & Documentation Requirements
Testing and documentation might be the last steps in a tank project, but they should still be discussed at the beginning. Inspection requirements, traceability expectations and turnover needs can influence project scope, scheduling and cost.
Documentation requirements can vary by industry, product and customer quality standards. Depending on your needs, you might require anything from material traceability reports to weld records to inspection reports and more.
When your tank manufacturing team is aware of these needs, they can plan them into the process, mitigating unexpected delays later.
Checklist
Pressure testing needs
Inspection requirements
Material traceability
Third-party witness requirements
Turnover Package (TOP) requirements
Documentation expectations
More is Always Better
You don’t need to know every answer before contacting Watson Custom Tanks about a new tank project. In fact, many processors come to us with only a portion of the information in hand. But by having all the information possible helps our team provide a better project scope.
When you contact us about a tank, our team’s first task will be to understand your product, process and operating needs. Our team has decades of experience, so they know the right questions to ask to fill in any information gaps.
The more we know, the more we can help you grow.
And in the end, you’ll receive a stainless steel tank solution that will safely and reliably meet your needs for years to come.
Ready to get started? Drop us a line now!
