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Expert Aseptic Processing Facility Design

Design aseptic food and beverage facilities with integrated architecture, process engineering, controls, sanitary design, and regulatory insight. Hixson helps manufacturers translate complex aseptic filling, thermal processing, CIP, hygienic zoning, utilities, and packaging requirements into buildable facilities that support food safety, production efficiency, future expansion, and confident commissioning across North American operations.

Aseptic beverage processing facility with stainless equipment

Our Aseptic Processing Facility Design Services

Integrated aseptic facility design services spanning process, packaging, utilities, controls, sanitation, and regulatory coordination.

Aseptic Design

Integrated planning and engineering for aseptic filling, sterile product handling, hygienic layouts, controlled environments, clean utilities, and documentation aligned with food safety and production goals.

Filling Lines

Process engineering for aseptic filling, bottling, canning, pouch, bag-in-box, line balancing, equipment selection, packaging integration, controls, and downstream secondary packaging systems.

Thermal Processing

Engineering for HTST, UHT, retort, batch and continuous cooking, heat exchangers, utility integration, controls, and time-temperature compliance documentation for food and beverage processes.

CIP Systems

CIP skid sizing, chemical storage, spray device specification, sanitation drainage, steam or hot water integration, cycle development, automation coordination, and validation-ready cleaning documentation.

Sanitary Design

Facility design using hygienic zoning, raw/RTE segregation, allergen control, cleanable finishes, sanitary piping, slope-to-drain floor design, and HACCP-supportive coordination.

Process Engineering

Process flow diagrams, P&IDs, equipment layouts, utility requirements, HAZOP reviews, procurement support, FAT/SAT, startup, and commissioning for complex manufacturing operations.

Engineers reviewing aseptic processing facility plans

Our Integrated Facility Design Process

Define Product And Capacity Requirements

Hixson helps define business goals, product requirements, packaging formats, capacity targets, and regulatory drivers before design begins. This early alignment clarifies aseptic processing needs, utility implications, food safety expectations, and future expansion priorities.

Map Process And Facility Flows

Integrate Engineering And Building Systems

Document Compliance And Sanitary Details

Support Construction Through Startup

Trusted By Leaders

Success Stories

Manufacturers rely on Hixson for complex food, beverage, science, technology, and workplace facility projects.

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis

"Very cool place with nice employees."

RaiderGreg
RaiderGreg

"Love it."

Zachary Waas
Zachary Waas

"Great Group of people. Thank You for supporting Special Olympics!"

Rebekah Travis
Rebekah Travis
The Hixson Difference

Why Choose Hixson?

Hixson brings specialized technical depth to complex aseptic manufacturing environments.

Integrated Team

Hixson coordinates 20 in-house disciplines to align process, building, utilities, and controls decisions.

Deep Expertise

More than 75 years of specialized facility experience supports complex food and beverage manufacturing decisions.

Risk Reduction

Aseptic, sanitary, CIP, thermal processing, and packaging knowledge helps reduce contamination and compliance risk.

Delivery Focus

Project management, estimating, and construction administration create continuity from planning through commissioning and startup.

Meet The Hixson Team

Experienced leaders across process, controls, architecture, and engineering.

John Brockmeier P.E. professional headshot

John Brockmeier P.E.

Manager, Plumbing Systems & Fire Protection Engineering

John oversees the department responsible for the design and engineering of plumbing systems and fire protection engineering for a variety of project types, including new construction, building utility upgrades, utility capacity analyses, and process line additions. John and his team work with a range of systems, including domestic water, process water, hot water production, direct contact water heaters, high pressure/rinse water, compressed air, natural gas, sanitary drainage, process drainage, central sanitation systems, fire pumps, and fire sprinkler systems.

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Craig Cheevers

Manager, Controls & Automation Engineering

As the Manager of Hixson's Controls & Automation department, Craig guides the team responsible for designing, implementing, and commissioning advanced control systems and automation solutions. His responsibilities include overseeing the development of automation strategies that streamline manufacturing processes, enhance operational efficiency, and ensure seamless integration of new and existing systems.

Warren Green P.E. professional headshot

Warren Green, P.E.

Manager, Process Engineering

Warren leads the team providing processing design services, process optimization studies, and process commissioning and FAT, SAT, and IQ activities. He advises on waste, energy, and GHG emissions reductions, and conducts safety and dust evaluations, including PSM/HAZOP. His expertise spans all food and beverage sectors including fluid, dried and cultured dairy products, processed meat, flavors, and prepared foods. Warren is also on the IDFA Food Safety Committee and actively participates in the 3A, SSI steering committee, and work groups.

Steve Guyer P.E. professional headshot

Steve Guyer, P.E.

Manager, Civil Engineering

In his role as Manager of Civil Engineering, Steve leads the team responsible for the planning, design, and engineering of roads, stormwater hydraulics and modeling, and onsite utilities. On project work, Steve is responsible for civil site project design, specifications, technical design, and project coordination with the client, government regulatory bodies, outside consultants, and contractors. As a senior staff member with our firm, Steve also serves as a mentor to newer associates.

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Chris Jarc, P.E., PMP, LEED AP

Vice President & Director, Project Management Services

Chris, a Hixson officer and member of the Board of Directors, oversees Hixson’s Project Management, Cost Estimating, and Construction Administration departments. Chris also serves in a project management role, leading teams consisting of representatives from the client, Hixson, contractors, and vendors to effective project completion. Chris assumes overall responsibility for development of project delivery strategies, coordination of all Hixson disciplines, and facilitating effective communication and management to focus resources on delivering high-quality projects on time and within budget.

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Dave Klenk

Manager, Mechanical Engineering

Dave brings more than three decades of experience to his role as the Manager of Hixson’s Mechanical Engineering Department. His work has included the design and project management of new facilities, as well as modification of existing facilities for high technology and food processing industries. At a corporate level, Dave is a member of Hixson’s Dairy and Beverage Industry team, which works to continuously improve the value Hixson offers to the dairy industry through development of our knowledge base, services and capabilities.

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Kyle McAllister

Manager, Electrical Engineering

Kyle serves as the Manager of Hixson’s Electrical Engineering department. In this role, he oversees the team responsible for the creation and delivery of electrical designs. This includes the design of high, medium, and low voltage power distribution, lighting, telecommunications, and fire alarm systems. Kyle brings more than 15 years of experience in electrical consulting and design to his role. Areas in which Kyle specializes include electrically hazardous area classification, high- and medium-voltage power distribution, protective relaying, arc flash studies, harmonics analysis, cogeneration design, emergency systems design, and complex laboratory designs.

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Scott McGlamery, P.E.

Senior Vice President, and Director, Mechanical & Electrical Engineering

Scott, an officer of the firm, leads the teams responsible for mechanical and electrical project tasks and design, specifications, technical content, consultation during equipment selection and installation and systems start-up assistance. In addition, Scott also serves as the Quality Assurance Manager, overseeing the firm’s commitment to quality. Over Scott’s more than three decades of experience, he has worked on greenfield, brownfield, and renovation projects for food & beverage plants in all sectors, labs, pharma & biotech facilities, and workplace projects.

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Scott Wever

Manager, Manufacturing Engineering

In his role as Manager of Hixson’s Manufacturing Engineering department, Scott leads the team responsible for project consulting and coordination between client, vendor, and internal disciplines within Hixson for overall manufacturing processes, functionality, equipment, and layouts. These team members develop process flow diagrams, equipment lists, and preliminary utility requirements, as well as develop equipment layouts that range from high level master planning to detailed construction documents. In addition to this role, Scott is a member of Hixson’s Meat Industry advisory team, focusing on technologies related to the meat and plant protein industry.

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Derek Wojcikowski

Director of Architecture

Derek is the Director of Hixson’s Architecture department. In this role, Derek leads the teams who design projects for our Food & Beverage, Pharma & Biotech, Laboratory, and Workplace clients. Previously, Derek served as the Manager of Hixson’s Process Layout department, where he directed the team that plays a critical coordination role in the overall development of process models and the 3D equipment model management process. Prior to these management roles, Derek, who began his career with Hixson in 2008, served as a Project Architect.

Frequently Asked Questions

What is an aseptic processing facility?

An aseptic processing facility is designed to commercially sterilize product and packaging separately, then bring them together in a controlled sterile environment. For food and beverage manufacturing, this may involve UHT or other thermal processing, sterile tanks, aseptic fillers, hygienic utilities, controlled airflows, validated cleaning systems, and layouts that protect product integrity from processing through packaging.

Why is facility design important for aseptic food and beverage manufacturing?

What products can be made in an aseptic processing facility?

What systems are included in aseptic facility design?

How does hygienic zoning reduce contamination risk?

Can Hixson support regulatory and food safety compliance?

Can an existing plant be converted for aseptic processing?

How do we start planning an aseptic processing project?

Have More Technical Questions?

Connect with Hixson to discuss your aseptic processing goals.

Service Areas Served

Hixson supports food and beverage manufacturers with facility planning and design services throughout North America.

North America

Service Area

1948

Founded

4.5★

Rating

Planning A Facility In Your Region?

Ask how our integrated teams can support your facility location.

Certified & Recognized

Awards and Recognition

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Great Place to Work

Recognition for workplace culture and associate engagement.

Giants of Design Rising Giants recognition logo

Rising Giants Recognition

Ranked No. 178 among emerging design leaders.

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Top F&B Firm

Recognized by leading food and beverage publications.

Plan Your Aseptic Facility With Confidence

Tell us about your product, process, capacity goals, and facility needs. Hixson will help define the right next step for planning, design, engineering, or project delivery support.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 513-241-1230. You can also send us a quick email at info@hixson-inc.com.