Project Overview

One of the largest bulk CBD suppliers in the U.S. approached FPE about designing and building their new production facility. After an initial feasibility study for process and facility requirements and the review of multiple existing building shells in which to house the new operation was completed, our firm implemented the design and construction for the project. The facility encompassed 125,000 sf for offices, raw and finished goods warehousing, hemp processing (pre-extraction, extraction, winterization, crystallization, remediation), purification, filling, and packaging.

The project involved many high-hazard, classified rooms due to various solvents involved in the process. FPE provided process P&IDs based on the client’s input, as well as architecture and engineering for the following, electric systems, backup generator, chilled water systems, air handling/ventilation systems, CO2 delivery system, natural gas distribution, process sewers, boilers, hot water system, compressed air, and exhaust air treatment.

Project planning, design, permitting, and construction for the project was implemented by FPE.

Flexibility for Growth

Creating and launching a new product in the food industry is an enormous undertaking. Once the product has been formulated and produced in a pilot plant, the process and production must be scaled up to meet the growing demands of consumers. Gathered Foods needed Food Plant Engineering’s food processing design and construction expertise to incorporate their proprietary vegan tuna process into their first large-scale, hygienic operation. Our team knew how to visualize the facility from start to finish and designed each space—from production to packaging—based upon not only the company’s current needs but on their anticipated growth. This project required a great deal of collaboration, as Gathered Foods looked to us for help sourcing equipment and meeting regulatory standards. We strived to maintain the unique integrity of their process and meet their overall needs.

To accommodate a growing business and a rapidly changing market, FPE allocated space in the facility design to allow for quadrupling the capacity of Gathered Food’s proprietary process and supporting processes, including freezing, mixing, forming, and packaging. The space was allocated to allow for the installation of additional processing equipment without expanding the footprint of the building. The layout can be adapted different production methods as new markets for vegan products arise. Opportunities for further building expansion were also considered when the existing space becomes fully utilized.

Food Processing and Packaging

While the core process for manufacturing Gathered Foods’ products is proprietary, Food Plant Engineering was responsible for integrating into the design the supporting food processing steps necessary to transform the initial product into its final form. After the propriety process—during which dry ingredients are transformed into the moist base product that replicates real tuna flakes—the flakes are processed using traditional food production methods to manufacture various products, including patties. Equipment used to produce the final products includes paddle mixers, vacuum fillers, plate formers, spiral freezers, and tunnel freezers. Patties are packaged in either a vertical form, fill, and seal machine or a horizontal form, fill, and seal machine. The secondary packaging includes carton and case formers and sealers. Metal detectors and checkweighers are used throughout the different stages of the process for food safety purposes. 

Facility Development

When developing a facility design, it is important to plan for the location of mechanical rooms, shipping/receiving docks, and utility entrances. These areas are difficult (if not impossible) to move if the building needs an expansion in the future. The location of these areas must be coordinated with other process support areas such as locker and break rooms, offices, chemical storage, and lab spaces. All areas must then connect with each other and the processing functions to allow for the flow of personnel, equipment, and trash in the facility. Often the solution for accomplishing this is to develop well-placed corridors for connecting the spaces. This project utilized a central corridor to separate hygienic zones, provide access to docks and mechanical areas, allow for the move-in of future equipment, and provide a connection for a future building addition. Knockout panels were added to the corridor for future freezers. Numerous gowning areas were placed along the corridor for employees to wash hands and put on PPE before entering more hygienic zones.

Flexible Lab Facilities

Research and development (R&D) and quality assurance (QA) labs were incorporated into the facility. The R&D lab was built as a multi-use space for product development, incorporating areas for food preparation, cooking, baking, and packaging operations. The QA lab was planned to allow for basic operations for sample retention and analysis. Using similar materials as the process areas, FPE constructed both spaces to comply with food safety standards. Added storage and open counterspace allow for flexibility as the business explores new products and continues to grow.

Project Management

Food Plant Engineering provided Project Management support for both the design and construction of the Gathered Foods facility. During the design phase, a Project Manager worked closely with the architectural and engineering teams to monitor the schedule. Weekly meetings with the owner were held to discuss the company’s needs, desires, and the requirements for the final design of the facility. Once the design was complete, the Construction Manager worked on-site directing the construction process and communicating with stakeholders regarding the budget and expenditures for construction.  

Finished Frozen Goods Storage and Shipping

A growing market for this hand-crafted ice cream producer created the need for additional storage space for their finished goods. The 150-year-old company decided to explore available options for creating additional storage space, and they selected Food Plant Engineering to assist with developing a master plan for growth. The demand for ice cream varies seasonally, but it can be stored for long periods of time due to its shelf life. Graeter’s employs the French pot method of producing ice cream in small batches, a procedure that does not allow for seasonal increases in production rates. Thus, the firm utilizes storage to build inventory during slower seasons. FPE performed various feasibility studies to review options for layout, size, and cost for additional freezer storage. This included developing storage off-site from current production operations and exploring options for building the freezer on-site as well.
 
The feasibility plan helped determine that constructing the storage facility at the existing site was the best option. While the facility was designed for future growth, the site location and boundary restrictions placed limitations on alternative construction materials and expansion itself. A code study was performed to determine viable options for expansion within the site parameters. Initially, it was determined that due to the addition’s proximity to the property line, a concrete or masonry wall was needed. However, our team was able to use calculation methods in the code for the allowed use of insulated metal panels for the walls, thus saving a significant cost in the construction when compared to concrete wall panels.

Our team developed the documents for constructing the facility using 3D BIM software. This allows the project team to easily view new addition integration within the existing facility. Such technology also helps to create a better plan for sequencing the construction and staging the construction shutdowns, thus allowing for production and warehousing operations to continue during construction.

This design-build project was implemented using an open-book process to determine the best value approach for selecting suppliers and subcontractors. This method gives owners the freedom to select and choose options for their project and permits them to allocate capital resources where most desired.  

When complete, the new freezer will quadruple Graeter’s on-site storage capacity, allowing the company to operate more efficiently and steadily build inventory to meet market demands throughout the year.

Process Feed Systems, Process Utilities and Dewatering for Guggisberg Processing Facility

A significant increase in the production of cheese created a need to increase the whey handling system capacity by 15-20 percent in order to concentrate whey, the primary byproduct of cheese production. The total solids in whey average approximately six percent after it is drained from the vats during the process of curd production. This whey can be further concentrated by removing the water, thus increasing the solid content. A new evaporator was installed to increase the solids to 32-45 percent, depending on downstream product needs. Significant cost and disruption were prevented when Food Plant Engineering’s team devised a way to install the evaporator within the existing facility structure.  

In order to implement this project, the existing evaporator needed to remain in operation while the new evaporator was installed. The plan also needed to allow for changeover of the production feed system to the new evaporator without disrupting production after the evaporator installation. The owner originally thought that a completely new building was needed to house the evaporator. However, working collaboratively with the manufacturer and the Guggisberg team, our firm was able to devise a way to install the new evaporator inside of the existing structure, and create an addition only for the fans, motor, and an electrical VFD control room.  

Utilizing this approach allowed for a streamlined changeover for the product feed system and evaporator utility feed. The downstream product HTST system was also replaced to add pasteurizing capacity for the increased volume of concentrate being produced from the new evaporator. 

To read more about our work with Guggisberg Cheese, see our whey expansion and evaporator installation project here.

Wastewater

The large volume of water generated as a result of concentrating the whey is commonly called “cow water.” This water can be recycled or reused, thereby reducing the demand for fresh water in the plant. The storage system for this water was enlarged and reconfigured to accommodate the increased production of cow water. Typical uses in the plant for this water is CIP pre-rinse and make-up water for the cooling and heating system.

Process Feed Systems, Process Utilities and Dewatering for Guggisberg Cheese Whey Processing

A significant increase in the production of cheese created a need to increase the Guggisberg Cheese whey processing handling system capacity by 15-20 percent in order to concentrate whey, the primary byproduct of cheese production. The total solids in whey average approximately six percent after it is drained from the vats during the process of curd production. This whey can be further concentrated by removing the water, thus increasing the solid content. A new evaporator was installed to increase the solids to 32-45 percent, depending on downstream product needs. Significant cost and disruption were prevented when Food Plant Engineering’s team devised a way to install the evaporator within the existing facility structure.  

In order to implement the Guggisberg Cheese whey processing project, the existing evaporator needed to remain in operation while the new evaporator was installed. The plan also needed to allow for changeover of the production feed system to the new evaporator without disrupting production after the evaporator installation. The owner originally thought that a completely new building was needed to house the evaporator. However, working collaboratively with the manufacturer and the Guggisberg Cheese team, our firm was able to devise a way to install the new evaporator inside of the existing structure, and create an addition only for the fans, motor, and an electrical VFD control room.  

Utilizing this approach allowed for a streamlined changeover for the product feed system and evaporator utility feed. The downstream product HTST system was also replaced to add pasteurizing capacity for the increased volume of concentrate being produced from the new evaporator. 

To read more about our work with Guggisberg Cheese, check out our facility expansion project with them here.

Whey Processing Wastewater Recycling

The large volume of water generated as a result of concentrating the whey is commonly called “cow water” (EcoLab PDF regarding best practices for cow water). This water can be recycled or reused, thereby reducing the demand for fresh water in the plant. The storage system for this water was enlarged and reconfigured to accommodate the increased production of cow water. Typical uses in the plant for this water is CIP pre-rinse and make-up water for the cooling and heating system.

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.

Project Overview

To meet increasing demand, this ready-to-eat protein division of a large international company selected FPE to design and construct an expansion at one of their facilities. The project was phased to keep the plant in operation during the construction. The project involved adding two high-volume, automated processing lines that required a 25,000 sf renovation and expansion of this 95,000 sf operating facility.

Additional circulation space and shipping docks were added as part of the upgrades. Two new automated grinding, forming, cooking, freezing, and packaging lines were also added to the facility. Major infrastructure upgrades included capacity and distribution additions for ammonia refrigeration, natural gas, steam and condensate, water heating, compressed air, and electric systems.

All project planning, design, permitting and construction for the project were implemented by FPE.

Project Overview

After a fire destroyed production capacity at one of their cooked meat facilities, a division of a large North American company turned to FPE for help regaining the lost production. The feasibility of rebuilding the fire-damaged facility and additional options were examined. As a result, the decision was made to implement a major upgrade to this legacy manufacturing facility.

A phased plan was developed to install two new cook lines in the building. The first phase involved installing a high-capacity cook line by carving out 15,000 sf inside of the facility for the automated meat grinding, forming, cooking, freezing, and packaging line. The project required significant infrastructure upgrades to support the two additional cooking lines. A new ammonia refrigeration system, steam boiler, water heater, natural gas service and distribution, electric service and distribution, oven exhaust system and treatment, and wastewater treatment were added alongside upgrades to existing infrastructure systems.

All project planning, design, permitting and construction for the project were implemented by FPE.

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.

Phased Approach to Project Implementation

More Than Gourmet first came to FPE to help determine the operational growth opportunity in their current facility. After a series of evaluations on their kettle operations, it was concluded that the system was at capacity, and only minor to moderate changes could be made to increase the throughput in its current state. With larger goals in mind, More Than Gourmet requested our help in doubling production capacity in their limited space. While maintaining production, the company needed to install new high-pressure kettles, extraction vessels, and concentration vessels. Along with these tasks, More Than Gourmet needed to relocate pasteurizing, filling and packaging operations in the current space and construct a facility addition for additional packaging, laboratory, and storage space.

Thus, the challenge of this project was developing a phased approach to minimize disruption to current operations. Complete understanding of the operation was necessary as we collaborated with More Than Gourmet’s team to time everything from the installation of equipment to construction milestones.   

The first challenge our team faced was the location for a new building addition. Due to site and property restrictions, the only option available was to attach the addition in the location of the current shipping and receiving docks. Since it was impossible for More Than Gourmet to operate without shipping and receiving for any length of time, our team developed a solution for installing a temporary dock for use during construction activities.  

The second challenge involved plant utility systems. After performing an evaluation of the natural gas, steam, water heating, and electrical systems, it was determined that upgrades were required for some of the utility infrastructure. The steam system required the installation of a new boiler to provide additional capacity necessitated by the installation of the new pressure kettles.  

Food Plant Engineering had to carefully plan and engineer the installation of the boiler to fit into the very limited space available in the existing mechanical room. Water heating also needed to be upgraded, so a larger, skid-mounted hot water system was installed to provide for the increased CIP and production needs. The electrical distribution system needed to be enhanced as well.  In order to implement these improvements, a series of well-planned, short plant shutdowns were implemented during which necessary tie-ins to the existing infrastructure were completed.

Food Processing System Design

More Than Gourmet specializes in making bone broth, a process that requires intricate piping and specialized process equipment. Our team studied the process, reviewed the existing P&ID drawings, and determined what changes were necessary in order to accomplish their goal of doubling production capacity. This solution involved installing a second custom kettle system alongside the existing kettles. Process improvements were also needed with the existing kettle operation to integrate the two systems and allow them to function as a combined system or as two separate systems. This approach allowed for a production operation that is flexible in terms of capacity and variations in production schedules.

The existing pasteurizing operation was not ideally located for good manufacturing practices.  Prior to aseptic packaging, the product passes through an ultra-high temperature (UHT) heat exchanger. Our firm devised a plan to improve food safety by relocating the pasteurization and packaging operation to a hygienic area created in the new building addition. Also, the bag-in-box and bulk filled containers did not have on-site storage available for the finished products. FPE was able to ingrate storage into the new addition to permit More Than Gourmet to hold more product on-site in a finished goods freezer. This also allowed for the bulk package products to remain on-site to supplement the supply of products for retail cup filling operations.   

In addition to developing plans for increasing capacity, other studies were performed to understand potential operational efficiency losses. These studies were performed to find solutions to improve processing efficiency and thus prioritize capital spending. The basic production process at More Than Gourmet involves extracting nutrients from animal by-products using temperature and pressure. The protein and nutrients are released into a broth; the broth is then concentrated, stored in holding tanks, and aseptically packaged into containers. The packaging operation that involves both retail packaging as well as institutional bulk packaging was studied. The cup and bottling filling lines were not performing as originally intended and solutions were devised to increase the uptime and efficiency of the operation.

Project Management

Food Plant Engineering provided Project Management support for all aspects of this project. During the design phase, the Project Manager worked closely with the architecture and engineering team to coordinate schedules. Weekly meetings between the Project Manager and the client during this time were used to explain how More Than Gourmet’s needs and wants affected the final design of the facility.  Once the design was complete, the Project Manager worked on-site to coordinate shutdown activities and to oversee the kettle system installation during the renovation. Additionally, the Construction Manager worked on-site to keep the new building construction on schedule and coordinate cash flow. 

Project Overview

One of the largest global food ingredient companies approached FPE to assist with increasing production at their Erlanger, Kentucky facility while daily operations continued. This project focused on two key areas in the facility: FPE was first tasked with the renovation of an existing production space designed for the staling, drying, and packaging of bread, stuffing, and seasoned croutons. After the completion of this work, our firm was then employed to design and build the space and infrastructure for a new bread crumb production line.

The initial renovation involved improving the facility infrastructure to support upgraded equipment, such as floor-mounted and ceiling-supported bread conveyors, loaders/unloaders, stackers/unstackers, dolly loaders/unloaders, bread slicers/dicers, bucket elevators, conveyor dryers, hoppers, and belt conveyors. An additional 8,000 sq. ft. room was designed for the drying oven and packaging equipment.  

The following expansion for a new bread crumb production line involved the design and construction of a 16,000 sq. ft. section of the facility to accommodate the following equipment: a mixer, sifter, overhead conveyors, an oven, proofer, pressure washer, two CW pumps, a hot water heater, and a boiler.

Throughout both parts of the project, FPE thoroughly reviewed options for air flow, zoning, and equipment, given the high-allergen environment and heavy potential for dust collection. A substantial review of the facility’s electrical demand was performed, and an additional transformer was installed to help fulfill the increased power requirements for both projects.

All project planning and design for the project were implemented by FPE.