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.

 

Sheetz

SHEETZ BROTHERS

Overview

  • Sheetz Brothers wanted to develop a new commissary facility including a bakery and ready-to-eat area to produce products that would be delivered fresh daily to the company’s 350 locations across six states.

Project Highlights

  • Dennis Group provided complete turn-key site development, facility, process design and construction management design-build services for Sheetz Brothers’ Kitchen new commissary facility in Claysburg, Pennsylvania. The project involved the construction of a new 140,000 SF commissary facility in conjunction with a 28,000 SF expansion to the existing Sheetz Distribution Center, as well as, other campus improvements.
  • Major accomplishments of the project included complete facility construction, process installation and commissioning in less than 12 months. This successful project was completed on schedule and exceeded expectation in many areas of design and performance. The facility has also been designed for future expansion to both the bakery and “ready-to-eat” areas.

 

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.

 

Coffee Facility

CONFIDENTIAL

Overview

  • The company 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.

 

Bakery Facility

CONFIDENTIAL

Overview

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

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.

 

Peanut Butter Facility

CONFIDENTIAL

Overview

  • The 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 three types of peanut butter 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.