We have Professional Engineering Licenses in CT, MA, RI, NH, NY and GA.

Whether it’s startup, process changes or decommissioning IRWIN blends sound engineering fundamentals with practical experience, to deliver high quality, value-added service in a timely, cost effective manner.


Conceptual design services:

  • process selection
  • process flow diagrams
  • material balances
  • facility layout and equipment sizing
  • economic optimization studies.

Detailed design phase services include:

  • piping and instrument diagrams (P&ID’S)
  • controls configuration and systems integration details
  • equipment specifications
  • installation instructions
  • utility plans.

Energy Recovery

Energy Recovery for Smoke and Odor ControlSpecialty Fabric Maker

IRWIN reduced utility costs 20% while resolving an odor and smoke discharge problem at this manufacturing plant.  By understanding the chemistry and engineering involved in the process, we were able to figure out and solve this client’s problem rather than just putting a bandaid on it. The change in process not only solved their emissions issue but saved them money!  First we tested our theories at the bench scale, before asking the client to make a real investment. Then, we constructed a pilot scrubbing operation, made some adjustments once it was operational and the regulators were satisfied.

Pollution Prevention & Toxics Use Reduction

IRWIN helps maximize process efficiency and minimize operating costs while reducing the use of toxic substances. Our CHEMICAL ENGINEERS provide insight and expertise in evaluating your unique situation and improving your processes. 2018 will be the next PLANNING YEAR. We are Certified for RESOURCE CONSERVATIONS PLANS as well as regular plans.
IRWIN has prepared, reviewed, or certified TUR Plans  or RC Plans for clients involved in:
  • Biotechnology
  • Copper wire drawing
  • Waste to energy
  • Printing
  • Membrane Technology
  • Aerospace
  • Lubricants & Adhesives
  • Furniture manufacturing
  • Wire & cable fabrication
  • Commercial sterilization
  • Textile manufacturing
  • Healthcare
  • Chemical manufacturing
  • Power generation
  • Musical Instrument manufacturing
  • Precision metal fabrication & Galvanizing
  • Fiber optic medical devices
  • Commercial Laundries


Water & Wastewater Design


Discharges to a Sewer

Disposal of industrial wastes via a Publicly Owned Treatment Works (POTW) requires a permit. These wastes are often subject to effluent pretreatment, monitoring and reporting requirements. Modifications to a facility’s operations may minimize the need for pretreatment resulting in cost savings. Bench scale testing (as pictured here) is another way to save money.

Surface Water Discharges

National Pollution Discharge Elimination System (NPDES) permits are required for surface water discharges. These permits must be renewed every five years. NPDES renewals can require an extensive amount of data and often raise new issues. Changes in receiving water body quality or concerns about thermal pollution may cause regulatory agencies to impose very stringent effluent limits. These restrictions can significantly affect your facility’s production and operating costs. Through our experience with NPDES issues, we help our clients to develop an effective permitting strategy.

Solvent Control/Slug Prevention Programs

Clients who discharge process wastewater to a publicly owned treatment works (POTW) are often required to submit documentation detailing how a facility will prevent the discharge of slugs or handle the discharge of solvents to avoid damaging the POTW.

High Purity Water Systems

Irwin Engineers has experience in designing potable water, USP 24/25 water, WFI, and micro electronics grade water systems. We can work with the client to design a new system, to increase the capacity of an existing system, or to improve water quality in an existing system. In these instances, high purity water needs to be treated as a key feed stock to manufacturing.


Risk Management/Process Safety

NEW REGULATION IN MASS FOR PROCESS SAFETY 527 CMR 33.00 applies below OSHA PSM levels. We work with Clients to ensure that the risks inherent in handling chemicals are properly addressed.  We work with our clients to implement or audit the implementation of OSHA’s Process Safety Management regulation or MA’s regulations, which are intended to protect workers and the public from chemicals released in work place incidents. The chemicals may be flammable, corrosive, toxic, and/or reactive. The OSHA standard covers 13 listed areas of owner/operator responsibility in an integrated approach to managing the risk. IRWIN can assist in writing a Process Safety Management Program, choosing the appropriate Process Hazard Analysis (PHA) for the facility, leading/documenting the Process Hazard Analysis, and auditing Process Safety Management compliance. For facilities covered by OSHA’s PSM regulations, PHA’s are required every five (5) years. For High Hazard Materials (HHM’s), Owner/Operators often opt to hold a PHA every three (3) years.

Spill Prevention Control & Countermeasure Plans

SPCC Plans are required for facilities with large amounts of oil1 storage:

  • Underground storage of 42,000 gallons or more; and/or
  • Aboveground storage of more than 1,320 gallons total in containers of 55 gallons or more in capacity.

These plans must be approved by a Professional Engineer and renewed every 5 years. The Plans contain descriptions of Good Engineering Practices for facility systems, procedures for avoiding spills and containment measures. IRWIN has developed an emergency Oil Spill Notification card for use in Massachusetts. Print it out for a handy reference.Read more

IRWIN adds value by conducting a detailed systems review for hazard assessment within the range of operating conditions and non-routine conditions. The assessment identifies key components that should be subject to regular preventative maintenance and/or testing. Spill pathway mapping and reporting protocols are also established.


SPCC Plans can also be part of a comprehensive Integrated Plan designed to address all aspects of Contingency Planning that apply to your facility. Material changes to your situation require you to update your Plan within 6 months of the change.

Note 1 – According to the U. S. EPA, the term oil means oil of any kind or in any form, including, but not limited to: petroleum; fuel oil; sludge; oil refuse; oil mixed with wastes other than dredged spoil; fats, oils or greases of animal, fish, or marine mammal origin; vegetable oils, including oil from seeds, nuts, fruits, or kernels; and other oils and greases, including synthetic oils and mineral oils.




IRWIN Engineers, Inc.
33 W. Central St.
Natick, MA 01760


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