Stonewall Kitchen

STONEWALL KITCHEN

Overview

  • What started as a jams and jellies line sold at farmers markets blossomed into more than 2,000 products for specialty food purveyor Stonewall Kitchen, who needed a new facility and corporate headquarters.

Project Highlights

  • This project involved development of an historically significant 8-acre greenfield site, as well as the fast-track development of a 50,000 SF facility for the processing and packaging of gourmet foods, a distribution center, corporate headquarters and a flagship retail store.
  • Major accomplishments of the project included the fact that site was challenged by wetlands restrictions, and is located in an historic district. The 50,000 SF facility had to be designed in such a way that it appears much smaller in scale than it actually is, and reminiscent of a New England family farm rather than an industrial production facility.

 

 

 

Ken’s

KEN’S FOODS

Project Highlights

  • Dennis Group completed a master planning study for the layout of a grass roots facility to be built in Las Vegas. The scope of the project included:
     
    • Developing a design basis for the new facility in terms of production and process system capacities
    • Determination of building size to meet current and future needs
    • Layout of the employee, process and utility areas of the facility including bulk liquid receiving by rail/truck
    • Layout of rocess areas for batch and continuous emulsion systems, starch preparation, cooking operations for sauces, dry ingredient blending and line layouts for high speed retail glass, food service, bulk tub and portion control lines
  • During the implementation phase of the project, Dennis Group provided complete building mechanical and electrical design, environmental design and permitting and coordination of architect, structural engineer, civil engineer activities for a 140,000 SF salad dressing plant.
  • Segregated waste systems and stringent sanitary design requirements were key features of this project.

 

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.

 

 

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.

 

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.
 
 
USGBC ® and the related logo are trademarks owned by the U.S. Green Building Council and are used with permission.

Sabra

SABRA DIPPING COMPANY

LEED New Construction v3 Gold
LEED New Construction v3 Silver
LEED New Construction v2.2 Silver

Overview

  • To meet rapid growth in the hummus and chilled dips sector, Sabra enlisted Dennis Group to provide full design-build services for the world’s largest hummus facility.

Project Highlights

     Named “Food Plant of the Year” by Refrigerated & Frozen Foods magazine

  • The initial facility was 120,000 SF which included a 40,000 SF finished goods distribution center – a 100,000 SF expansion was added later in less than 14 months from concept to commissioning.
  • Dennis Group took a highly manual operation in Sabra’s former location in Astoria, New York and transformed it into a fully-automated operation giving Sabra a more than 200 percent capacity increase.
  • A custom integrated CIP system ensures the product is never exposed to the manufacturing environment and that the finished product is not handled until it has been hermetically sealed.
  • The project attained LEED Gold and LEED Silver Certifications for energy savings, environmental impact and sustainability.
    • A massive water collection system allows for the reuse of 500,000 gallons of rain and process water each year
    • Low VOC levels were specified for all paints, coatings, sealants, adhesives, and carpet systems
    • Composite wood products are free of urea-formaldehyde
    • Outdoor air ventilation far surpassed the recommended guidelines of ASHRAE

 

 
USGBC ® and the related logo are trademarks owned by the U.S. Green Building Council and are used with permission.

Dips & Spreads

Manufacturers of dips and spreads need a partner that understands how to design a process for their particular operation that works with the latest sanitation technology – because even small deposits can lead to microbial growth of potentially dangerous organisms.  Closed systems are designed to be Cleaned In Place (CIP’ed) and all equipment and process areas are designed for thorough sanitation procedures and inspection.

Dennis Group has worked with spreads, dips and sauces with a range of characteristics, including:

  • Peanut butter
  • Hummus
  • Salad Dressing
  • Ketchup, mustard, mayonnaise
  • Jellies and jams
  • Shelf-stable cheese spreads
  • Dairy-based dips
  • Pasta sauce
  • Syrups / High fructose corn syrup

We designed and built Sabra’s new LEED gold certified facility, which was honored as Refrigerated and Frozen Foods’Food Plant of the Year” for innovations in automation, sanitation and sustainability. It was the first manufacturing facility in Virginia to earn LEED Gold New Construction Certification from the U.S. Green Building Council.