Snack Food Facility Transformation & Expansion

To meet the growing demand for their products, a Snack Food company launched an extensive modernization and expansion project at their facility in Wisconsin. JP Cullen served as the EPC partner, providing design assistance, overseeing construction, and self-performing key parts of the project, including equipment installation. The project kicked off with the removal of 360,000 pounds of outdated equipment and steel from the early 1990s. For the first week the crews worked 12-hour shifts around the clock and were able to drop down to a single shift 10-hour operation after the first week. All work was executed while the plant’s adjacent departments remained in operation.

Key highlights from the project included:

• Installation of new conveyors and equipment to separate small and large chips, along with sanitary platforms for improved equipment accessibility.
• Addition of four new automated packaging lines, automation of all remaining lines, and replacement of packaging conveyance systems with Heat and Control Fastbacks for optimized chip distribution.
• Installation of 12 new seasoning lines supported by a newly constructed equipment platform.
• A facility expansion featuring an existing concrete mezzanine for cardboard storage, alongside new areas for washer units, seasoning storage, and equipment storage.
• Construction of a new electrical room outfitted with switchgear, switchboards, and various electrical panels.
• Creation of a new warehouse equipped with racking systems to house seasoning supplies.

The project was successfully completed ahead of schedule, reflecting our team’s dedication to efficiency and planning.