This “fast track” construction renovation/expansion project took only thirty-two weeks from conception to completion without any interruptions in the production facility’s operations. The Shambaugh team mobilized and began onsite construction services within two weeks and completed the project on schedule.
Innovations and additional value added items and tasks included:
- Redesign of the facility master plan to allow for subsequent facility expansions
- Reduced capital cost by redesigning the existing process and utilities to make more efficient use of in-plant equipment
- Eliminated costly relocation of existing sugar tank
- Sized the HTST heat exchanger, separator, and homogenizer for future expansion
- Incorporated continuous standardization
- Go from batch standardizing to standardizing milk “on the fly”
- Doubled production from 450,000 to 950,000 jugs per day
- Adding new equipment to include HTST pasteurizer, filler, palletizer, tank alley and ingredient tanks
- Detailed survey of all food process, packaging, and plant utilities
Kroger needed to double the capacity at its fluid milk and by-products bottling facility located in Tolleson, Arizona.
Scope of Services
The first eight weeks of the Design-Build construction project were dedicated to conceptual design, identification, specification, selection, and procurement of long-lead major equipment items, and preparation of the overall construction project budget.
- Construction of new raw tank silo alley
- New HTST pasteurize, pasteurized surge, and filler
- Redesign and expansion of cream cooling, storage and load-out
- Design-build and installation of empty case handling, washing, case packing and palletizing
- New orange juice concentrate receiving, storage, and blending operation
- Expansion of ammonia refrigeration system and redesign of cooling media distribution throughout the facility
- Replacement of the entire process control system with state-of-the-art PLC and touch screen operator interface terminals