Heinz

HEINZ

Overview

  • HJ Heinz European Frozen and Chilled Foods invested $9 MM to establish a strategic headquarters in Dublin and expand its frozen ready-meals production facility.

Project Highlights

  • Dennis Group provided facility and process design-build services for the expansion of an Heinz’s existing facility located in Dundalk, Ireland. The facility design included renovation of 5,000 m2 of internal production space and the construction of 3,000 m2 of new food manufacturing and utility areas.
  • This project involved the installation of two high-speed fully automated frozen-ready meal production lines.
  • A state of the art sauce manufacturing system utilizing vacuum cooling and a flexible batch management and control system supported the production lines.
  • Additional process equipment included pasta blanching, high shear slurry blending, and potato and fish handling.
  • Installation of completely new utility systems and a wastewater treatment plant was also incorporated into the project.

 

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.

 

Maidstone Bakeries

MAIDSTONE BAKERIES

Overview

  • Maidstone Bakeries was a joint venture between Tim Hortons and Cuisine de France to commercialize a cutting-edge technique that “flash freezes” par-baked donuts, fritters and crullers as soon as they leave the fryer. The facility supplied sweet baked goods and baguettes to the network of popular Tim Hortons franchises across Canada and North America.

Project Highlights

  • This fast-track design-build project went from planning to completion in less than 12 months.
  • A 31-acre site was developed as well as a 230,000 SF facility which included a 40,000 SF storage freezer and 40,000 SF office space.
  • Site preparation, adjoining caissons/foundations, expandable building design, and mechanical/electrical system sizing all provided flexibility to allow for future expansion.
  • Dennis Group was involved in two subsequent expansions which increased the size of the facility to 400,000 SF.

 

 

Ahold

AHOLD

Overview

  • In order to comply with new Massachusetts regulations preventing the disposal of food waste in landfills, Ahold sought a way to beneficially reuse unsalable organic material from their grocery stores throughout the New England region, resulting in the development of an anaerobic digester.

Project Highlights

  • Dennis Group designed and built a Product Recovery Operation (PRO) at Ahold’s distribution center. The PRO facility consists of equipment capable of processing 130 tons of food waste daily, converting the waste into feedstock for a 1.3 MM gallon anaerobic digester.
  • Biogas produced for the anaerobic digestion process powers a 1.1 MW generator, providing renewable energy to power the distribution center.
  • The facility reduces Ahold’s food waste to landfill by 25,000 tons annually.
  • The PRO plan produces 30% of the distribution center’s electricity.
  • Dennis Group was able to secure $1.3 MM in energy efficiency rebates and grants for the project.

 

La Brea Bakery

LA BREA BAKERY

Overview

  • La Brea Bakery had overextended the production capacity of their west coast facility and was on a fast track program to expand sales in the eastern United States.

Project Highlights

  • Dennis Group was engaged as a partner to assist La Brea in their efforts to increase the production capacity by constructing a new facility on the east coast. Complete interior fit-up, MEP and construction management design-build services were provided for a new bakery facility.
  • The Swedesboro facility houses the largest automated artisan bread production line in the world. The project involved the fast-track fit-up of a 190,000 square foot facility including a 20,000 square foot storage freezer and 7,500 square feet of office space.
  • Major accomplishments of the project included complete design with smooth integration of production systems supplied by equipment manufacturers located in four countries. The facility has been designed and constructed to allow for easy capacity expansion in the future.

 

Ahold

AHOLD

LEED New Construction v3 Certified

Overview

  • Project involved the development of a greenfield regional meat processing and packaging facility for Ahold USA/Vantage Foods. Ahold is the parent company of Stop and Shop and Giant supermarket stores and the new facility provides fresh, case ready, meat products to these store chains through New England, Pennsylvania, and Northern Maryland.

Project Highlights

  • Dennis Group provided LEED administrative services for the project which included project credit submission, tracking, start up and commissioning, and final submission to the United States Green Building Council. Upon completion of this effort, the facility received LEED Certified status.
  • Specific technical features of the project procured, managed, and constructed by The Dennis Group include a 24,000 lbs ammonia refrigeration system with 5 compressors, approximately 65,000 SF of refrigerated meat processing space, a multi-bay receiving and shipping dock, complete ESFR sprinkler system with a fire pump, and diesel back up generator.
  • The facility also boasts a complete onsite waste water treatment facility with two lift stations.
  • Site work development included grading, storm water management, parking, and secured access, and a two story employee service area, with locker rooms, cafeteria, and office space.
  • The project is currently producing in excess of 1 million pounds of packaged meat weekly. In addition, the project team was able to pass a rigorous USDA inspection of the facility on the first attempt, which speaks to the quality of construction and attention to sanitary detail.

 

 

 
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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.