Project Service: Process Piping Design

Ocean Spray

OCEAN SPRAY

Overview

  • When global demand for Ocean Spray dried cranberries doubled within three years and was projected to double once again, the company made its largest capital investment in a manufacturing facility to date with a 130,000 SF expansion that doubled the plant’s size to 440,000 SF. The plant produces both sweetened dried cranberries and cranberry juice concentrates.

Project Highlights

  • The facility incorporated some of the latest technologies in energy and environmental efficiency, including a wastewater  treatment facility, energy-efficient lighting, and an expansion of a system that converts methane from the Veolia Cranberry Creek Landfill into clean energy to power the plant.
  • A new fully-racked warehouse for both ingredients and finished goods increased storage capacity. The expansion enabled the plant to produce more than 30 million pounds of sweetened dried cranberries per year.
  • Major accomplishments of the project included design and implementation of 5S standards in creating state-of-the-art maintenance shop and quality control lab spaces.

 

Ken’s

KEN’S FOODS

Project Highlights

  • Dennis Group completed a master planning study for the layout of a grass roots facility to be built in Las Vegas. The scope of the project included:
     
    • Developing a design basis for the new facility in terms of production and process system capacities
    • Determination of building size to meet current and future needs
    • Layout of the employee, process and utility areas of the facility including bulk liquid receiving by rail/truck
    • Layout of rocess areas for batch and continuous emulsion systems, starch preparation, cooking operations for sauces, dry ingredient blending and line layouts for high speed retail glass, food service, bulk tub and portion control lines
  • During the implementation phase of the project, Dennis Group provided complete building mechanical and electrical design, environmental design and permitting and coordination of architect, structural engineer, civil engineer activities for a 140,000 SF salad dressing plant.
  • Segregated waste systems and stringent sanitary design requirements were key features of this project.

 

Dole

DOLE

Overview

  • Dennis Group teamed with Dole to develop the design for a forward processing plant in the Midwest. Dennis Group worked with Dole to develop the process and then designed the facility around the needs of that process.

Project Highlights

  • Dennis Group assisted Dole with site selection, and once the site selection was finalized, developed the site, executed preliminary and detailed engineering of the building, erected the building, designed the process and process utilities, installed the process equipment, and commissioned the facility to operate all in under one year.
  • In addition to the original facility, the Dennis Group executed two expansions to the Dole Springfield facility. The Dennis Group provided design/build services for a 30,000 SF warehouse expansion, and for a 25,000 SF expansion to house processing and packaging of fresh cut fruit.

 

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.