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Modular Systems: Why They Are The industrial Process Plant’s Clear Choice

Modular systems. They are beneficial in many ways for the industrial process plant industry. Traditionally speaking, stick built systems came first, while modular systems are a product of modern developments. You will need to select between these two systems, which is not a straightforward decision.

Several key factors will contribute to your final decision. If you haven’t yet made your choice, here are the four definitive reasons why modern modular systems are the superior choice, and why you should look into them.


How to choose between modular and stick built systems: 4 factors

Quality, cost-effectiveness, scheduling, and system accountability - if you are going to make the best decision when choosing between modular and stick systems, these are the factors to contemplate. But what do each of these factors mean in terms of modular and stick built systems?

  • Quality refers to the quality of the module’s assembly and whether it needs to be reworked at any point. The higher the quality, the cost savings, and the fewer the risks.
  • Cost-effectiveness includes anything from transportation costs to engineering costs, labor costs and installation, staffing to energy costs, maintenance to capital.
  • Scheduling is a factor that can impact your choice between modular and stick built systems. The fewer scheduling delays the better.
  • In terms of system accountability, this relates to whether your system matches your needs for your project. A technician should be on hand to respond to any issues linked with your system.

What are the key differences between stick built systems and modular systems?

Essentially, modular systems outperform stick built systems in several ways. The table below outlines some of the advantages of modular over stick built.

Key Factor Stick Built Modular System
Quality Unstable quality Offers reliability and top quality
Time Requires preparation time Significantly saves time
Cost High cost, low gains in performance Lower cost
System accountability Several salespersons One vendor, accountable for any issues

As indicated by the table, modular systems have the edge. They are the clear choice as their cost, quality, time, and system accountability are all the best options compared with stick built systems.


Why are modular systems the ideal industrial process plant industry solution?

To provide further insight into modular systems and their benefits, here are the specifics in terms of each of the above factors.

Modular system vs stick built: quality

The main reason modular systems exceed the quality of stick built systems is their reliability. Coupled with their exceptional design that is critical for efficiency, the way they are manufactured makes modular systems second to none.

The expert labor, added to the procedures that are undertaken during the manufacturing process of modular systems, is far more rigorous when carried out within particular environments. Specifically, when modular systems are manufactured in environments that are controlled, the better the results.

Modular systems undergo quality testing for factories. Their components must match certain acceptance requirements and are expertly chosen to fulfill these requirements for many industries, including:

  • Oil refining
  • Gas processing
  • Chemical
  • Petrochemical
  • Power, and
  • Oil and gas

Using modular systems vs stick built: time

Unlike stick built systems, you will find that modular systems streamline productivity and enhance the speed with which projects are accomplished. The main reason for this is that the environments in which manufacturing takes place are controlled ones.

In these controlled environments, not only can experts can carry out processes efficiently, but they can also create a modular system regardless of delays that could occur due to the weather.

Add to this the benefit that there is a significant minimization of initiation time and you can see why modular systems help you save time. Given that modules are all assessed before shipping and arrive fully assembled, these tasks are no longer required.

Modular systems vs stick built: cost

Modular systems are incredibly cost-effective, particularly when you compare them to stick built systems. The reason for this cost-effectiveness is that their designs can potentially be reused, but also that:

  • Labor costs are lower
  • Fewer materials are required because pipe runs are shorter
  • Expert fabrication technicians can work consistently, and
  • There is less need to rework, which keeps wasted time and money to a minimum

Even though the engineering costs might be higher, the duplication of modular system designs greatly reduces these costs.

Using modular systems vs stick built: project schedules

There is an added advantage of using modular systems vs stick built: the reduction in project scheduling. As mentioned, delays caused by the weather are avoided because the work takes place within module construction yards.

When we compare this with stick built systems, the timelines and schedules of projects are significantly reduced.

Modular systems vs stick built: the reduction of risk

There are various reasons why modular systems are a better risk mitigator than stick built systems. The conditions under which these modular systems are created are better when compared to stick built systems.

Modular systems are also system tested before they are shipped. Crews also work fewer OSHA exposure hours when constructing these systems. They are therefore safer for use and safer when being built.

Explore modular systems for your process plant and experience quality

Given the quality, cost, risk, and time advantages you get with modular systems, they are the ideal choice when compared with stick systems. In summary, modular systems:

  • Reduce risks
  • Enable projects to be completed with speed
  • Offer top quality
  • Cost less, and
  • Can be used across many industries

Modular systems are the superior choice. Get more information on plant engineering solutions and products at

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