Early Insights, Lasting Impact: The Case for Modularization Studies

November 10, 2025

A modularization study is a powerful tool for shaping a project early in its lifecycle. With just a few inputs—like a heat and material balance, process flow diagram, and layout constraints—engineers can begin sizing equipment and exploring how the plant might be divided into modules. These early insights help clarify layout challenges, operational needs, and the impact on cost and schedule.

The true value of modularization studies lies in their ability to guide strategic decisions before detailed design begins. By evaluating equipment size, maintenance access, interconnections, and fabrication versus installation locations, teams can determine which areas suit modular construction and which are better stick-built. Logistics are also key; transportation, site access, and installation windows often shape the modular strategy as much as the process design.

Beyond feasibility, these studies can validate plant scale and sometimes reveal opportunities to downsize without sacrificing performance, or scale up within the same budget. They also help define scope boundaries for technology providers, EPC partners, and suppliers, reducing overlap and improving collaboration.

One recent example: Zeton completed a modularization study in just two weeks using minimal data. The results showed the original design was oversized, leading the client to scale down by a factor of ten while maintaining functionality. This early insight streamlined execution and boosted confidence.

Modularization studies are more than technical evaluations, they’re strategic tools that lay the foundation for efficient, scalable, and cost-effective plant designs.