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DANNON
WATER BOTTLING FACILITY
Mt. Shasta, CA
Design
Criteria
Construction of a new spring water bottling plant designed
to bottle “From the Source” spring water. The 161,373
square foot facility is composed of warehouse, process
and office areas and services the western United States.
Facilty Group was selected to provide planning,
detailed architecture, engineering, and construction
services.
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The plant is designed with two production lines and
the capacity to add three additional lines in the
future.
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The plant has the ability to produce 36,000 bottles
per hour for each production line installed.
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The production lines consist of state of the art Blowers,
Unscramblers, Fillers, Palletizers and Complete Conveying
Systems.
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Process lines are designed to fill 8oz to 1.5 liter
PET bottles at an average of 600 bottles per minute.
PET bottles are shipped to the facility as preforms
and blown on site with state of the art blowing equipment.
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The project is ongoing and will be completed on schedule
and within budget.
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GUINNESS
UDV - FACILITY CONVERSION AND START-UP
Lehigh Valley, PA
Design
Criteria
Guinness UDV introduced the malt beverage Smirnoff Ice
in 2000. The success of this product and the interest
in introducing other new products in this category caused
Guinness UDV to have an immediate need for additional
production capacity. Facilty Group assisted in
the evaluation of an idle brewery as a way to get that
capacity quickly. Facilty Group was able to evaluate,
procure, install, overhaul and retrofit both the processing
area & equipment and the packaging area & equipment
so that the facility was reopened and the first bottling
line producing saleable product 6 weeks after the purchase
of the brewery. Each of the next two bottling lines
started in 6-week increments after the first line. Some
of the unique characteristics of this project were:
- Extremely
aggressive time table (1st line in 6 weeks)
- Facility
had been shut down
- No
time for detailed engineering drawings
- Process
and packaging both had extensive modifications
- Required
full time on site engineers
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80-90 construction personnel working 12 hour days
7 days a week
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IAMS - DRY PET FOOD PLANT
Coevorden, Netherlands
Design Criteria
Facilty Group was retained to provide engineering
and project management services for a new 255,000 square
foot dry pet food manufacturing and packaging facility.
- The $110 million facility was completed on fast-track
schedule and operational in 19 months.
- The new IAMS plant is fully automated with an 8,000+
point control system. It includes three bulk transfer
systems (corn, all other grains, fish/poultry meal)
and a liquid system capable of supplying four processing
lines at the same time with an independent metering
system.
- All systems have electric heat tracing and insulation
on the stainless steel lines and the tanks are hot
water jacketed and insulated. The plant also contains
a cooler capable of reducing product temperature from
43.3° C to within 2.8° C of ambient.
- Facilty Group provided building engineering,
process engineering, site selection, city negotiations,
equipment procurement, construction and testing services
for this project. The facility was completed ahead
of schedule and within budget.
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MEADOWBROOK
FARMS, INC. - PORK PROCESSING FACILITY
Rantoul, IL
Design
Criteria
American Premium Foods, Inc., an Illinois co-operative
made up of over 250 family farms selected The Facility
Group to provide turn-key process planning, equipment
selection and procurement, architectural, engineering
and construction management for a greenfield 90,000
square foot hog slaughter facility. The process is highly
automated to support production of high quality and
specialty “value added” meat products such as fresh
sausage and case ready pork for retail grocery chains.
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Planned as a state-of-the-art 400 head per hour slaughter,
case ready and further processing operation
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Designed to provide expansion to a second shift
- Advanced
technology including kill floor robotics and carcass
evaluation and data collection systems
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addition to the carcass addition system is the ability
to use the acquired data in “real time” to benefit
sortation at the cooler and to realize the maximum
yield for each carcass
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Design achieves optimal meat quality through the minimization
of time between kill and carcass chill
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