Coffee Facility

CONFIDENTIAL

The company consolidated their coffee operations from Kansas City, KS and Sherman, TX to New Orleans, LA to defray shipping costs.

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.

A new greenfield facility was built on a 35-acre site to produce a popular line of frozen baked goods.

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.

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.

In order to ensure long-term competitiveness and meet growing demand, the company decided to build a 300,000 SF facility that embraced the latest equipment and technologies on its corporate campus.

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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