The project consisted of complete interior demolition and remodel of an existing plant that manufactures sliced deli meats for Sara Lee under the Hillshire Farm® and Sara Lee® Deli brands. The existing facility was comprised of a first floor of approximately 180,000 square feet and a second level of 45,000 square feet.
All interior walls, floor slabs, ceilings, processing equipment, above- and below-ground waste and process piping, HVAC systems, refrigeration systems, and electrical distribution systems were completely removed and replaced with new, state-of-the-art systems. New additions totaling 15,000 square feet were added, along with new site improvements, new roof, and building facade upgrades. The completed facility is a world-class leader in deli meat production, processing, slicing, and packaging, operating at efficiencies and standards never achieved before.
Innovative engineering processes and “no touch” robotics reduce processing time by 50% compared to conventional manufacturing and require half of the employees normally required to operate such a facility.
Because of the fast track schedule, the roofing and interior finish work needed to occur concurrently. In order to preserve the integrity of the finish work during roofing construction, a temporary roof was installed as a cost-effective solution to enclose the building so both processes could continue unhindered.
The client’s ultimate goal was increased production efficiency by decreasing clean cycle time. This was accomplished by installing higher quality finishes to eliminate crevices, innovative curb design, and modification of utility design details.
Multiple mock-ups were used throughout the process to demonstrate detail improvements and verify quality expectations with the owner.
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