The reconstruction of existing production facilities is one of the most challenging engineering tasks in the modern agro-industrial complex. Unlike green construction, working at an existing enterprise requires a delicate balance between innovation and continuity of production processes.
The design and construction company CHIEF has accumulated unique experience in this field, having implemented dozens of large-scale modernizations without a single day of downtime. The practical case of integrating the Van Aarsen granulation line at the facilities of Agrolife LLC demonstrates how engineering discipline translates into a competitive advantage for the customer.
The philosophy of continuity: from equipment replacement to system optimization
The traditional approach to modernization boils down to simply replacing outdated equipment with modern equivalents. The DCC CHIEF team rejects this simplistic logic in favor of systematic analysis.
“Our goal is not just to replace old equipment with new,” explains Anna Panchuk, the company’s chief technologist. “We analyze the entire technological chain and look for bottlenecks. Sometimes it turns out that instead of buying a new granulator, we first need to modernize the dosing or steam conditioning system. This gives better results and makes more efficient use of the customer’s budget.”
This approach proved to be critically important in the project for Agrolife LLC, a modern agricultural enterprise in the Lviv region, which decided to radically expand its production capabilities without stopping existing capacities. Instead of selectively upgrading individual units, DCC CHIEF specialists conducted a comprehensive survey of existing communications and load-bearing structures, developed a work schedule with minimal interference in the production cycle, and ensured the integration of new modern equipment with the gradual phasing out of the old. The result was a complete modernization without stopping production.
Technological expertise as a competitive advantage
The choice of a technology partner determines the economic efficiency of a project for decades to come. For Agrolife LLC, this choice fell on the Van Aarsen granulation line — equipment that combines Dutch engineering tradition with adaptability to local conditions. The status of DCC CHIEF as the official representative of Van Aarsen in Ukraine provided direct access to the manufacturer’s modern technologies and prompt delivery of original spare parts.
The philosophy of “co-creation” promoted by Van Aarsen found its ideal embodiment in this project. The Dutch company provided cutting-edge technology, DCC CHIEF provided engineering expertise and installation experience, and Agrolife LLC provided an understanding of local market needs and the specifics of the raw material base. This three-way synergy made it possible to adapt standard solutions to the specific production conditions in the Lviv region.
People are the key element of a culture of quality. The engineers and technologists employed by DCC CHIEF not only have the relevant education and experience, but also undergo systematic training directly with equipment manufacturers, including at the Van Aarsen factory in the Netherlands.
“It is important for us to understand not only the theory, but also the technological philosophy of our partners: quality, reliability, and service for decades. We saw how each node undergoes control at every stage of production,” says Alexander Chumachenko, director of DCC CHIEF.
This provides a unique advantage: Ukrainian specialists know the equipment not from the instructions, but from the inside — they understand its design features, potential “bottlenecks,” and optimal operating modes. Returning to the customer’s site, they act not only as installers, but also as technical consultants capable of optimizing the operation of the equipment for specific production conditions.
The transformation of Agrolife LLC’s production capabilities illustrates the practical value of comprehensive modernization. Prior to the project, the company was limited to producing loose feed and premixes — products with a limited shelf life and high logistics costs. The launch of the granulation line radically changed this paradigm.
The new line produces pellets ranging from 2 mm in diameter for young poultry to 5–6 mm for cattle. Energy efficiency has increased by 15–20% per ton of product. Logistical flexibility allows products to be shipped both in bulk and in packaged form. For the regional market, this means access to high-quality feed that is competitive with imported counterparts in terms of price and superior in terms of freshness.
Van Aarsen equipment is known for its operational reliability — some mixers installed in Ukraine more than 25 years ago continue to operate without major repairs. DCC CHIEF reinforces this advantage with comprehensive service support: scheduled and unscheduled maintenance, supply of imported spare parts, and training of customer personnel.
“This project is a vivid illustration of our philosophy: we don’t just install equipment,” says Alexander Chumachenko, director of DCC CHIEF. “We become technical advisors, helping customers get the most out of their investments — from logistics optimization to staff training. The result: the line operates flawlessly, at its rated capacity.”
In modern agribusiness, which is increasingly becoming a complex infrastructure industry, even minor mistakes can be very costly. It is not enough to simply build walls and install equipment — you need to think systematically, anticipate how the facility will operate in different modes, during and outside of the season, during peak loads and at a normal pace. When design is carried out according to this principle, no detail is overlooked. This is especially important when reconstructing existing production facilities, where any intervention can lead to downtime and financial losses. The company’s team has learned to work in stages, carefully planning each step so that modernization takes place without interrupting the technological cycle.
“There is only one level of responsibility for details,” emphasizes Anna Panchuk, chief technologist at DCC CHIEF. “From the reliability of connections on silos to the accuracy of automation system settings, each element undergoes multi-level control.”
This experience illustrates the fundamental transformation of the role of the general contractor in the modern agro-industrial complex. Whereas previously a construction company performed the function of a technical contractor, today DCC CHIEF positions itself as a project consultant responsible for the economic efficiency of the customer’s investments.
“We invest our own time in studying the client’s technological processes,” emphasizes the director of DCC CHIEF. “This allows us to offer solutions that optimize not just a single node, but the entire production system.”
This methodology is implemented through a full cycle of commitments: from design to commissioning. Our reputation, forged over 16 years of market presence, requires uncompromising responsibility for every element of the system.
The portfolio of completed projects by DCC CHIEF covers the entire territory of Ukraine — from Lviv to Kharkiv, from Sumy to Zaporizhia. Its international presence includes successful projects in Kazakhstan, Turkmenistan, and European Union countries. Its partners include key players in the Ukrainian agro-industrial complex: Nibulon, MHP, Krupets, Vitagro, Cargill, Cedrob, Trouw Nutrition Ukraine, Bontrup Agriculture, AGROL, Ukrlandfarming, Koudays, and Ovostar Union. This geography demonstrates the versatility of the methodology: regardless of the region and scale of the customer, the principles of continuous modernization and systemic responsibility remain unchanged.
The Agrolife case demonstrates that successful reconstruction of an operating enterprise is only possible with the synergy of three factors: strategic choice of technology, official representative status for equipment, and a comprehensive approach by the general contractor. DCC CHIEF guarantees that even the most complex technological tasks will be performed with European quality and Ukrainian reliability. The story of Agrolife is just one of many examples of how a professional approach to details transforms investments into a stable and effective business.