Major Facility Expansion

Aryzta began long term planning for an expansion of their facility, but following a period of quicker than planned growth, the need to expand became critical as orders to some major clients were being shorted. Dennis Group was engaged to immediately begin planning for a fast-track expansion project.

Since schedule was critical, a phased approach to design, permitting, and construction was utilized, where all phases happened simultaneously. For example, permitting and procurement activities started within 1 week of start of detailed design, and construction started within 6 weeks of the start of detailed design.

The project took place in the heavily regulated environment of Los Angles and Southern California. Permitting was identified as a critical path activity from the start and was therefore a main challenge.

The construction size was 75,000 SF, with the site only extending 60’ beyond the building. During the height of construction there were more than 300 contractors on site per day with around the clock activities. Daily management of construction activities was critical, and the project was completed with no major safety incidents. The process core was turned over to the plant within four months from the start of construction.