In an effort to reduce costs and improve efficiency, this leading food processor contacted our team to assist with decommissioning two plants and the subsequent consolidation of equipment into one of its existing facilities. Completed in under of a year, this project included two substantial additions (net 19,500 sq. ft.) and a major interior remodel of the impacted plant. The project was delivered in three separate packages (north addition, south addition, and interior remodel) with minimal operational downtime.
- Fast-track schedule and timely delivery.POWER completed the entire project in less than one year, despite a dynamic schedule and scope. Four start-ups occurred precisely on time.
- Proactive, cooperative partnerships. Engaged with vendors/contractors early to help expedite the schedule.
- Upgraded sanitary classifications. Improved an area of the existing facility to support USDA standards. Facility went from 18 existing CIP circuits (17 active) to 20 active circuits.
- Continuous production. Despite the scale of this project, the existing plant was able to continue running its production lines with little-to-no down time.
- Multidiscipline coordination on site. Over 30 POWER employees from five offices dedicated themselves to this project. Our team was onsite to perform line verifications and we assisted the Owner’s plant team with initial flushes and passivation.
- North Addition: This expansion was required to house relocated equipment. Minimal space to expand and continued operation were challenges we successfully navigated.
- South Addition: We worked closely with the Owner’s staff to provide design options to fit relocated equipment into as much existing space as possible while being conscious of egress and building separation codes.
- Interior Remodel: Substantial areas of the existing facility were gutted and rebuilt to implement the Owner’s proposed product lines.
- Expansions increased usable production space. Added 19,500 square feet to the existing facility, remodeled a total of 94,134 square feet.
- 3,000 gallon recovery tank saves 2,500 gallons of water each wash. This tank runs 20 CIP circuits, 15 of which are programmed to run on any given day.
- The main 15kV switchgear feeding the plant was heavily modified for more efficient power distribution.
- Managed the relocation and re-commissioning of 100 power distribution and control panels.
- Provided design and coordination services to improve efficiencies in the production flows
- Seamless coordination among structural, process, packaging, mechanical, electrical, controls, and architectural disciplines
- New process area lighting designed for 78,000 sq. ft. New non-process area lighting was designed for 23,000 sq. ft.
- Updated the facility by implementing the Owner’s strict hygienic and industry standards throughout the newly created/modified spaces
- Relocated/installed full facility sanitation equipment including Clean in place (CIP), Clean out of place (COP), post stations, hygiene systems, and hose stations to support hygienic zoning