Project Service: Process Design

Dole

DOLE

Overview

  • Dennis Group was enlisted to design and build the Dole Fresh Flowers World Headquarters facility in Miami, Florida.

Project Highlights

  • This state-of-the-art 328,000 SF facility combines 250,000 square feet of 32º ± 0.5º refrigerated space with 78,000 square feet of corporate offices located on an 18 acre site.
  • Dennis Group maintained a fast-track schedule for this project.

 

Dole

DOLE

Overview

  • Dennis Group provided complete site, facility and process design, procurement and installation services for this greenfield site.

Project Highlights

  • The project included development of a 100 acre site and construction of a 280,000 SF processing facility to house production equipment for the making of prepared salads and cut vegetables.
  • Major accomplishments of the project include balancing a site that required over 500,000 cubic feet of cut and fill, working with the state to install a 100,000 gallon waste water retention tank, installation of a 2000 ton ammonia refrigeration system, and installation of equipment to produce 500,000 lbs. of salad per day.

 

Sheetz

SHEETZ BROTHERS

Overview

  • Sheetz Brothers wanted to develop a new commissary facility including a bakery and ready-to-eat area to produce products that would be delivered fresh daily to the company’s 350 locations across six states.

Project Highlights

  • Dennis Group provided complete turn-key site development, facility, process design and construction management design-build services for Sheetz Brothers’ Kitchen new commissary facility in Claysburg, Pennsylvania. The project involved the construction of a new 140,000 SF commissary facility in conjunction with a 28,000 SF expansion to the existing Sheetz Distribution Center, as well as, other campus improvements.
  • Major accomplishments of the project included complete facility construction, process installation and commissioning in less than 12 months. This successful project was completed on schedule and exceeded expectation in many areas of design and performance. The facility has also been designed for future expansion to both the bakery and “ready-to-eat” areas.

 

Dole

DOLE

Overview

  • Dennis Group teamed with Dole for the design and construction of a greenfield operation in Helsingborg, Sweden.

Project Highlights

  • Included was development of a 4-acre site, and the design and construction of a 55,000 SF facility for the processing and packaging of ready-to-eat fresh salads.
  • This project also included the design and installation of four automated processing and packaging lines, including the first fully automated drying operation within the Dole organization.
  • Additionally, the entire project was designed around an efficient future building expansion that would incorporate a total of 8 processing lines

 

Coffee Facility

CONFIDENTIAL

Overview

  • The company consolidated their coffee operations from Kansas City, KS and Sherman, TX to New Orleans, LA to defray shipping costs.

Project Highlights

  • This project was a consolidation and included the relocation and installation of 12 coffee roasters, 4 packaging lines and blending and grinding equipment from their Kansas City facility as well as coffee silos from a facility in Sherman, TX.
  • Areas of the existing facility were renovated to create a new plant entrance, amenities and better GMP controlled access to the operation.
  • An existing section of the facility was removed and a 140 foot tall 50,000 square foot processing tower was constructed.
  • This project included the addition of utility infrastructure (aspiration, compressed air, tower water, chilled water, and fire quenching systems), as well as a separate flavor storage building with automated delivery and cleaning systems to support the production lines.
  • Construction and installation was executed without impact to the plant’s existing operation, and the shutdown, relocation and startup of assets from the Kansas City facility was completed without impact to the supply of product to customers.

 

Bakery Facility

CONFIDENTIAL

Overview

  • A new greenfield facility was built on a 35-acre site to produce a popular line of frozen baked goods. 

Project Highlights

  • Speed-to-market was key to meet growing consumer demand, and this fast-track project which included a 188,000 SF bread bakery, automated sandwich assembly and packaging line, went from site design to commissioning in under 12 months.
  • The campus encompassed a 20,000 SF finished goods storage freezer, refrigerated shipping docks and 18,000 SF of office space.
  • Future expansion needs played a role in both the building design and the utility system sizing, and subsequent projects executed by Dennis Group have enlarged the footprint to 320,000 SF.

 

 

Dreyer’s

DREYER’S

Overview

  • Shortly after the merger between Nestlé and Dreyer’s Grand Ice Cream, the decision was made to consolidate manufacturing and distribution functions at the Operations Center located in Bakersfield, CA.

Project Highlights

  • This expansion consisted of adding over 320,000 square feet of processing, utility, warehouse/distribution, and R&D space, including six new production lines.
  • In addition to three conventional ice cream mix production tanks, the facility includes a yogurt production room. This space is pressurized to preclude infiltration of airborne contaminants. 3000 gallon batches of cream are inoculated with live yogurt cultures to produce the base yogurt mix. The mix is batch pasteurized, then pumped to surge tanks for addition of flavors, prior to freezing, hardening and packaging.
  • Once the expansion was completed, in fewer than 12 months from groundbreaking to saleable product, Dreyer’s manufacturing throughput was doubled.

 

Peanut Butter Facility

CONFIDENTIAL

Overview

  • The company converted a former jams and jellies facility into a processing space for peanut butter.

Project Highlights

  • Dennis Group provided full design-build services for the project, which included building a complete renovation of the existing warehouse in addition to a large expansion to support a robust production line.  
  • A highly integrated vertical operation in excess of 100’ in height was constructed with a focus on gentle handling. 
  • A new rail infrastructure was added to receive shipments of peanuts and included an “in motion” scale for raw material tracking.  
  • Raw versus roast (HACCP) zoning was established to separate the high care and low care peanut processing spaces. 
  • The facility currently produces three types of peanut butter on this high speed production line.