Project Service: Utility System Design

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.

 

Dole

DOLE

Overview

  • Dennis Group teamed with Dole for the design and construction of a greenfield operation in Helsingborg, Sweden.

Project Highlights

  • Included was development of a 4-acre site, and the design and construction of a 55,000 SF facility for the processing and packaging of ready-to-eat fresh salads.
  • This project also included the design and installation of four automated processing and packaging lines, including the first fully automated drying operation within the Dole organization.
  • Additionally, the entire project was designed around an efficient future building expansion that would incorporate a total of 8 processing lines

 

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.

 

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.

 

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.

 

Greenfield

CONFIDENTIAL

LEED New Construction v3 Certified

Overview

  • 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.

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.
 
 
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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.