- Coffee Cake Bakery
- 3528 Browns Mill Rd SE
- Atlanta
- GA
- 30354
- United States
- Featured Article Order:
5
- Project Header:
Coffee Cafe Bakery
- Project City, State:
Atlanta, Georgia
- Project Highlight 1:
Bakery operation consisting of a thoroughly automated process of mixing, proofing, and frying product
- Project Highlight 2:
Specialty production area featuring cooling, icing, and filling a small variety of donut products
- Project Highlight 3:
An additional power transformer and generator with an automatic transfer switch provided supplemental power to facility
- Project Counter 1 Value:
31,000
- Project Counter 1 Units:
sf facility build-out
- Project Counter 2 Value:
2
- Project Counter 2 Units :
high-volume, automated donut fry lines
- Project Counter 3 Value:
1
- Project Counter 3 Units:
specialty production area
Project Overview
With the goal of producing donuts in a central facility for their network of franchise stores, a group of owners reached out to FPE to build out a former storage facility. Although the 31,000 sq. ft. building once housed a food warehousing operation, significant infrastructural upgrades had to be made to accommodate a commercial baking process as a Dunkin Central Manufacturing Location. Notable among these accommodations were a new plumbing system, the demolition of several coolers/freezers, and upgraded rooftop HVAC equipment.
The project site was landlocked between two neighboring buildings and a decommissioned railroad at the facility’s rear, each within several feet of the property line. With limited space for construction materials and equipment in the parking lot, the scheduling and execution of key phases of facility construction and process installation was critical. Another factor our team had to consider was the facility’s proximity to Hartsfield-Jackson International Airport, whereby an FAA permit was obtained to lift and install rooftop HVAC units.
All project planning, design, permitting and construction for the project were implemented by FPE.
- Featured Article Order:
1
- Project Header:
International Delights
- Project City, State:
Clifton, New Jersey
- Project Quote:
You listen - The people doing the work are the great value of Food Plant Engineering. It’s not something you find everyday--such capability, personality and character
- Project Quote Author:
Spiro Sayegh, Managing Partner
- Project Highlight 1:
New production facility for pastries, croissants and muffins
- Project Highlight 2:
Implementation of automated oven and packaging lines
- Project Highlight 3:
Implementation of jam and chocolate topping production and sourdough capabilities
- Project Counter 1 Value:
1
- Project Counter 1 Units:
automated lamination and oven line
- Project Counter 2 Value:
180,000
- Project Counter 2 Units :
square feet bakery
- Project Counter 3 Value:
3
- Project Counter 3 Units:
automated packaging lines
Process improvements for a repeat client
International Delights has continuously added processing capabilities since our firm designed the original 180,000-square-foot bakery in 2010. Innovation has always been at the core of the company’s mission, and when they determined that the industry did not produce fillings and toppings to meet their needs, International Delights decided to begin producing their own. This vertical integration allows the company to control the quality and cost of their fillings, icings, and jams. The company also decided that roasting their own nuts would allow them to create a better chocolate filling and spread from scratch. The new production capability enables them to produce their own chocolate and hazelnut spreads and to produce jam with 70 percent fruit content. Additionally, packaging machinery was installed to produce stick packs, thus allowing for the sale of single-serving squeezable spreads with the bakery products.
The company also added a sourdough operation to incorporate this fermented dough into select products. This addition will extend shelf life and provide a cleaner label for these items. Three tons of sourdough are made daily using International Delight’s proprietary system.
Fermentation System
Food Plant Engineering’s team worked with the equipment supplier to create a process layout for the sourdough production. The fermentation system included fermentation vessels, flour scaling and feed systems, circulation and feed pumps, a heating and cooling system, and product pumping. Our firm developed the design and layout for the cooling, heating, and vessel feed systems using the parameters and technology from the equipment manufacturer. The chillers and boilers for the process control were also selected and specified. Room environment is also important to produce sourdough. Proper control of the air is necessary to prevent phage proliferation within a plant and limit potentially problematic phages from creating issues with the sourdough cultures. Thus, a hygienic room environment with positive air pressure-that utilizes filters and conditioned air was designed for this operation.
Filling Production
Equipment for the roasting of nuts, ball mills for creating the nut paste, and the stick pack machine for filling were selected for the batch production of nut pastes. Our firm assisted International Delights with the application of the equipment, providing advice on options, layouts, and production methods. The layout and design of all the process utilities including gas, equipment venting, and sanitation were performed by our firm. The room finishes and air flows were designed by Food Plant Engineering as well.
Jam Production
A vacuum cooking process to produce jam was installed. The equipment included fruit cutting/chopping, vacuum cooking, and mixing. Our firm provided the engineering for the process equipment utilities systems including vacuum, heating, and cooling equipment selection and installation design.
- Featured Article Order:
4
- Project Header:
Malt Products
- Project City, State:
Dayton, Ohio
- Project Highlight 1:
Challenging site required large amount of earthwork
- Project Highlight 2:
Highly efficient lighting and heating system installed
- Project Highlight 3:
Flexible racking layout allowing for changing storage needs
- Project Counter 1 Value:
170,000
- Project Counter 1 Units:
sf warehouse addition
- Project Counter 2 Value:
10
- Project Counter 2 Units :
dock doors
- Project Counter 3 Value:
13,280
- Project Counter 3 Units:
pallet positions
Project Overview
A large wholesale supplier of natural sweeteners to the baking industry approached FPE with a need to increase on-site storage for finished goods. As a result of shortages during the pandemic, customers requested that the company hold a greater inventory. The company enlisted FPE to study options for expanding their on-site storage. A concept was developed to construct a 170,000 sf warehouse for the first phase of the project, with a future second phase planned.
To accommodate the addition, a large amount of earth was moved and a new storm water detention system was put in place. During the planning phases, a variance was obtained for the project. The project also involved adding new shipping docks, breakrooms, and offices for the warehouse staff.
All project planning, design, permitting, and construction for the project was implemented by FPE.