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.

Dreyer’s

DREYER’S

Overview

When Dreyer’s combined its ice cream business with that of Nestlé’s, expansion of East Coast manufacturing and distribution capacity was one of the highest priorities in rationalizing the merger. Dennis Group was selected as a partner for the evaluation and execution of this major facility and process expansion project.

Project Highlights

The project involved acquiring and re-zoning 40 acres of property, increasing the size of the facility six fold to over 600,000 SF, creating a 23,000 pallet minus 20 degree distribution center, and adding 10 new ice cream and frozen yogurt lines.

This major undertaking was affected over a two year construction period, and was accomplished without sacrificing a single minute of the existing facility’s available capacity.

Greenfield

CONFIDENTIAL

LEED New Construction v3 Certified

Overview

In order to ensure long-term competitiveness and meet growing demand, the company decided to build a 300,000 SF facility that embraced the latest equipment and technologies on its corporate campus.

Project Highlights

This new space, which was located adjacent to an existing finished goods warehouse on their 35-acre corporate campus featured rail receiving, bulk dry and liquid commodities, three high-speed production lines and five portion control lines.

Dennis Group adopted a phased construction approach in order to seamlessly transition operations from an existing facility.

Careful planning and permitting were required since the site had several wetland areas. In addition to mitigating the wetland disturbance, sustainability was a key focus of the project since the company has committed to be environmentally conscious and socially responsible.

USGBC ® and the related logo are trademarks owned by the U.S. Green Building Council and are used with permission.

MOM Brands

MOM BRANDS

Overview

Following the launch of Malt-O-Meal;s Better Oats® line of instant oatmeal products, the company undertook a two-phase $136 million expansion of its Asheboro production facility.

Project Highlights

Dennis Group provided complete design-build services for an expansion to Malt-O-Meal’s Asheboro facility which included development of a 35 acre site, including a new rail siding for unloading bulk grains, a rail receiving building and a 550,000 sq ft. two level building addition constructed of pre-cast and cast in place concrete as well as structural steel.

The site also includes a retaining wall approximately 20’H by 500’ to make up for the elevation difference between the rail siding and remainder of the site.

The expansion also included the construction of a 80,000 sq ft. warehouse for storing packaging materials and finished product.

This project included the addition of utility infrastructure (chillers, air compressors and hot water system), eleven bulk commodity bins, and two bulk liquid storage tanks. The process additions included the installation of three complete cereal production lines with fully automated final packaging.