Dennis Group provided consulting services for the development of a greenfield site in Osaka, Japan for Baskin Robbins.
The project consisted of a new ice cream production facility for producing 3 gallon (13.6 L) bulk containers and novelty ice cream cakes for this global manufacturer of ice cream products.
Dennis Group provided site, facility, process, and packaging development in order to generate a cost estimate for capital approval.
The project required collaboration with the client’s local consulting engineers for process and facility designs. Development of a final cost estimate required an extensive value engineering phase in order to deliver the preliminary project plan at desired capital level.
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.
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.
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.
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.
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.
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.