USDA Frozen Food Manufacturing Facility Brownfield Plant Renovation

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Location: Southeastern US

Our client, a leader in the frozen food industry, was looking to expand their operations into a new region.  Originally they were considering a “greenfield” approach, but found an opportunity in a 150,000 SF, three-year old, abandoned beef slaughtering and further processing facility.

Initially, POWER assisted our client with an assessment of this potential “brownfield” site to ensure that the basic site, building and infrastructure, utilities, and sanitary design aspects were compatible with their expectations, as well as convertible for their needs, given the required capital expenditure for the building and expected facility transformation.

Once the decision was made to proceed, POWER provided an extensive due diligence review of the site to clear it for purchase, as well as decommissioning review support to ensure the purchased facility and assets had been kept in good condition.  We also worked with our client to develop a master plan to define the renovation of this facility for conversion into a highly sanitary food plant with new processes in place and also taking into account for short term and long term site growth.

Once those basic plans were approved, POWER provided full engineering services through final design on a near fast track basis completely transforming a mid-sized beef processing plant into a USDA frozen food manufacturing operation.  Working closely with our construction management partner, we delivered a bid-build approach for construction, which provided the best value and lowest cost for our client.

Near the end of the project, POWER managed the move of significant process equipment from another facility into the new one.  Utilizing a knowledgeable team, the entire move of the processing lines took less than six weeks, even though the installation of the equipment in the new facility required extensive modifications.

At the project end, we provided complete installation, commissioning, and start-up support for shared processes and high speed manufacturing lines.  The final result is a “state of the art” food manufacturing facility, delivered at a fraction of the cost of a new facility.