Hi Gee technology is emerging as an alternative to conventional tray and packed towers for mass-transfer applications. To evaluate the process intensification (volume reduction) potential of the technology, a systematic design procedure is developed in this work. Hi Gee designs using split packing innovation of Chandra et al. [Ind. Eng. Chem. Res. 2005, 44, 4051-4060] are developed for four industrially relevant distillation and absorption systems. Comparison with conventional packed or tray tower designs shows that significant volume reduction is possible. For the systems studied, the process intensification achieved is particularly impressive when the gas side mass-transfer resistance is dominant. The results suggest that split packing design innovation may be particularly suitable for intensification of gas side mass-transfer resistance controlled processes.