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

Daisy Brand

DAISY BRAND

Overview

Daisy Brand is the premier manufacturer of sour cream in the United States, producing a fresh product without preservatives which is consistently voted the “best in class”. Demand for the company’s products has outstripped the capacity of their sole facility in Garland, Texas and a decision was made to construct a second manufacturing plant.

Project Highlights

Casa Grande, Arizona was chosen as the site of the new facility, owing to its proximity to several major dairy farms, as well as increased and for the company’s products in the southwestern U.S.

The new facility was constructed on a 36 acre site, formerly used to grow cotton. The building encompasses 200,000 SF (150,000 SF footprint). Provisions were made for a future addition of 20,000 SF for production of the company’s newest product, cottage cheese.

Folgers

FOLGERS

Overview

Folgers 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.

The J.M. Smucker Company

THE J.M. SMUCKER COMPANY

Overview

A new greenfield facility was built on a 35-acre site to produce The J.M. Smucker Company’s very popular thaw and serve peanut butter and jelly sandwich line.

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.

The J.M. Smucker Company

THE J.M. SMUCKER COMPANY

Overview

The J.M. Smucker 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 JIF Creamy, JIF Crunchy and JIF Natural products 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.

The J.M. Smucker Company

THE J.M. SMUCKER COMPANY

LEED New Construction v3 Certified

Overview

In order to ensure long-term competitiveness and meet growing demand, The J.M. Smucker 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.

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