When the largest privately owned dessert manufacturer in Canada reached capacity in its Delta, British Columbia plant, it looked east to Ontario, at the heart of the North American market.
To facilitate the shipping of frozen decorated cakes, this 130,000 SF facility had a Variable Retention Time (VRT) freezer, the largest of its kind at the time, with 1000’ of conveyer in eight different cells at -10˚F.
Thanks to close coordination, the project was completed in 11 months from groundbreaking to saleable product, despite a winter with unusually high snow falls.
It received a gold rating from the American Institute of Baking (AIB) due to sanitary design practices that exceeded AIB and GMP standards, and production rates were higher than expected immediately upon start-up.
After Campari Group purchased Wild Turkey the decided to invest $100 MM in the Lawrenceburg, KY facility in order to bring all bottling and packaging in-house once again.
Dennis Group was responsible for the design and construction of a grassroots bottling plant for Wild Turkey at its distillery in Lawrenceburg, Kentucky. The facility was designed to produce Skyy vodka, flavored vodkas, Wild Turkey bourbon, American Honey and various specialty bourbons and featured three high-speed bottling lines with room for a future fourth line.
The building was constructed on a very hilly site with an excess of 25 feet elevation difference in the original topography resulting in a massive cut and fill operation; a considerable amount of blasting was needed to remove ledge.
The project features an outdoor tank farm for incoming spirits, capable of holding up to 300,000 gallons of product, a 15,000 SF blending room with 400,000 gallons of blending and bottling tanks and a 40,000 SF bottling hall.
The upstairs office core was designed with a viewing mezzanine to allow Wild Turkey to conduct visitor tours of their operation and the facility has become an important stop on Kentucky’s Bourbon Trail.
StockPot, a subsidiary of Campbell Soup Company, produced fresh-refrigerated soups, entrées, sauces, chilies, gravies, and side dishes. All products emphasized freshness and quality, using fresh-cut vegetables, genuine dairy products, fresh herbs and spices, and premium meats and seafood.
Dennis Group provided complete design-build services for StockPot’s new greenfield facility project in Woodinville, WA, but their business had tripled in a short time, so Dennis Group was once again engaged when they required a second new facility on an 18-acre site.
The new soup manufacturing facility doubled the size of their production capacity, as well as implemented an expanded state-of-the-art clean-in-place (CIP) system to accommodate the made-to-order soup runs while improving production efficiency of StockPot’s unique cook, chill and packaging systems.
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.
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.
Kellogg’s Ontario facility that produced the Mini-Wheats branded cereal made a $43 MM investment to add a new cereal production line that made use of advanced food manufacturing technologies.
Dennis Group provided complete site, facility, and process design for this expansion project at the Belleville, Ontario, Canada facility. The project included the renovation of approximately 76,000 SF of existing building shell (fit up of slabs, UG plumbing, walls, etc) to facilitate the installation of a new 30MM pound/year DX cereal line.
Major accomplishments include going from KAR approval to saleable product in 11 months, all while working in an existing operating facility.
The project also required the removal and replacement of a 5,000 SF section of the existing buildings roof and replacement with a 100psf blast resistant roof to house the new mix room.
Dennis Group was brought in shortly after a catastrophic series of explosions destroyed much of Imperial Sugar’s refinery & packaging facilities. Following investigations conducted by OSHA and the U.S. Chemical Safety and Hazard Investigation Board (CSB), Dennis Group was released to begin management of site/facility demolition while simultaneously planning for the design-build reconstruction of the site and facilities with “world class” vision.
11 months following project release and commencement of construction, key operations for Imperial Sugar were back on line.
Scope included 185,000 SF of new building construction plus 40,000 SF of damaged facility renovations and new production and packaging equipment.
300 tons/hour of sugar was distributed via dense phase systems (with dilute phase systems for powder & starch conveyance), three large storage silos constructed & fit up, truck and rail load out reconstructed with updated technologies, and eleven high volume packaging lines (granulated, brown and powder) all with the most current NFPA, OSHA and CSB recommendations, guidelines & requirements. Extensive wet and dry dust collection systems were incorporated into the design.
Maintaining schedule and cost while incorporating design innovations and working around existing site constraints were major challenges overcome during this fast-track project. Once key elements of production were on line construction of facilities and installation of process equipment were performed without interruption to ongoing operations. This required close coordination with plant personnel, 24 hour per day construction activities and managing over 600 contractors per day during peak installation & commissioning periods.
When global demand for Ocean Spray dried cranberries doubled within three years and was projected to double once again, the company made its largest capital investment in a manufacturing facility to date with a 130,000 SF expansion that doubled the plant’s size to 440,000 SF. The plant produces both sweetened dried cranberries and cranberry juice concentrates.
The facility incorporated some of the latest technologies in energy and environmental efficiency, including a wastewater treatment facility, energy-efficient lighting, and an expansion of a system that converts methane from the Veolia Cranberry Creek Landfill into clean energy to power the plant.
A new fully-racked warehouse for both ingredients and finished goods increased storage capacity. The expansion enabled the plant to produce more than 30 million pounds of sweetened dried cranberries per year.
Major accomplishments of the project included design and implementation of 5S standards in creating state-of-the-art maintenance shop and quality control lab spaces.
Maidstone Bakeries was a joint venture between Tim Hortons and Cuisine de France to commercialize a cutting-edge technique that “flash freezes” par-baked donuts, fritters and crullers as soon as they leave the fryer. The facility supplied sweet baked goods and baguettes to the network of popular Tim Hortons franchises across Canada and North America.
This fast-track design-build project went from planning to completion in less than 12 months.
A 31-acre site was developed as well as a 230,000 SF facility which included a 40,000 SF storage freezer and 40,000 SF office space.
Site preparation, adjoining caissons/foundations, expandable building design, and mechanical/electrical system sizing all provided flexibility to allow for future expansion.
Dennis Group was involved in two subsequent expansions which increased the size of the facility to 400,000 SF.