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.

 

 

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.

 

MOM Brands

MOM BRANDS

Overview

  • Following the launch of Malt-O-Meal;s Better Oats® line of instant oatmeal products, the company undertook a two-phase $136 million expansion of its Asheboro production facility.

Project Highlights

  • Dennis Group provided complete design-build services for an expansion to Malt-O-Meal’s Asheboro facility which included development of a 35 acre site, including a new rail siding for unloading bulk grains, a rail receiving building and a 550,000 sq ft. two level building addition constructed of pre-cast and cast in place concrete as well as structural steel.
  • The site also includes a retaining wall approximately 20’H by 500’ to make up for the elevation difference between the rail siding and remainder of the site.
  • The expansion also included the construction of a 80,000 sq ft. warehouse for storing packaging materials and finished product.
  • This project included the addition of utility infrastructure (chillers, air compressors and hot water system), eleven bulk commodity bins, and two bulk liquid storage tanks. The process additions included the installation of three complete cereal production lines with fully automated final packaging.

 

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.