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Consulting

Consulting &Plant Projects

Greenfield development  ·  Brownfield upgrades  ·  Commissioning  ·  Operations audits

21+
Years in Galvanizing
9
Plant Projects
3
Plants Operating
10+
Countries

Plant Work,
Not Presentations

Every engagement is run by the engineer who built and operates galvanizing plants: 5 built from zero and 4 upgraded, 3 of them operating today. The scope below is the work that has actually been done, not a menu.

🏗️
Greenfield Plant Development
Site feasibility, layout, kettle and tank-line sizing for the market you will actually serve, equipment procurement, civil construction supervision, commissioning and first production.
🔧
Brownfield Upgrades
Kettle replacements and extensions, fuel conversions (diesel to LPG), automation, closed-line retrofits with scrubbers and zinc dust filters, and process rebalancing after the change.
🚀
Commissioning
Trial runs, operator training and handover to production, with the record-keeping and KPIs in place from the first commercial batch rather than bolted on later.
🔍
Operations Audit
Process, quality system and cost review of a running plant: pickling and flux control, kettle practice, dross and ash, inspection and records. Findings ranked by what they cost you.
📊
Zinc Reconciliation & KPI Setup
Zinc consumption benchmarking, dross and ash recovery analysis, chemical and fuel efficiency, variance analysis, and a KPI dashboard the plant will keep using after the visit.
📋
Standards Compliance
ASTM A123/A123M-24, A153, A780 and ISO 1461:2022 in practice: specification review, inspection and test regime, non-conformance handling, customer complaints and supplier qualification.

Three Steps,
No Retainer Required

01

Remote review

Send the drawings, the production numbers or the problem. You get a first assessment and a proposed scope by email or call before anyone travels.

02

Site visit

Where the question needs eyes on the plant: layout, kettle practice, bath chemistry, records and the people running the line.

03

Report

Findings, options and a ranked action list written so it can go to the board and to the shop floor without translation.

Where the Work
Gets Done

On site across the Gulf and Egypt, and remotely for plants anywhere that can share drawings and numbers.

GCC Egypt Remote worldwide

Tell Us the Plant, the Market and the Problem

One email is enough to start. Describe the plant or the project, the market it serves and what is not working, and you will get a straight answer on whether and how it can be helped.