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New, ground-up facility for processing and packaging Angus beef located just outside Idaho Falls, ID.
It was constructed primarily of pre-cast concrete walls and insulated metal panels with a cast-in-place concrete basement. The plant is a modern processing facility with the capability to process animals from harvest to finished packaged product. The building layout includes a large fabrication area with state-of-the-art equipment, 28-degree box cooler, -10-degree freezer, multiple Hot Box chillers, a cold dock with eight dock-height doors, order fulfillment space, a two-story office, and various support spaces. In total, the facility requires seven (7) different temperature zones.
The plant utilizes a covered anaerobic lagoon to capture and pre-treat animal waste, a small wastewater treatment building to finish the process, and an on-site biogas and reuse building that transforms processed waste into solid fuel to heat the building.

New, ground-up facility for processing and packaging Angus beef located just outside Idaho Falls, ID. It was constructed primarily of pre-cast concrete walls and insulated metal panels with a cast-in-place concrete basement. The plant is a modern processing facility with the capability to process animals from harvest to finished packaged product. The building layout includes a large fabrication area with state-of-the-art equipment, 28-degree box cooler, -10-degree freezer, multiple Hot Box chillers, a cold dock with eight dock-height doors, order fulfillment space, a two-story office, and various support spaces. In total, the facility requires seven (7) different temperature zones.
The plant utilizes a covered anaerobic lagoon to capture and pre-treat animal waste, a small wastewater treatment building to finish the process, and an on-site biogas and reuse building that transforms processed waste into solid fuel to heat the building.

Riverbend Ranch Meat Processing Plant Exterior

Idaho Falls, ID

Construction

Food & Beverage Processing

National Food Beverage

Riverbend Ranch Meat Processing Plant

Design-build delivery for a state-of-the-art fluid milk facility constructed of tilt-up concrete panels, insulated metal panels, and conventional steel construction.
Interior spaces include dry and cool warehouse space, a large palletizing and packing room, milk processing areas, and employee support areas such as a locker room, open office space, and a lunchroom. The project also included site development with a wastewater treatment facility, concrete and asphalt paving, landscaping, and associated sitework.
Suntado is the first vertically integrated class 1 and class 2 dairy processing plant in Idaho, able to process and package products in one location. The plant handles up to 1 million pounds of milk per day and produces a variety of dairy products, from extended shelf-life items to ultra-pasteurized, shelf-stable milk.

Design-build delivery for a state-of-the-art fluid milk facility constructed of tilt-up concrete panels, insulated metal panels, and conventional steel construction. Interior spaces include dry and cool warehouse space, a large palletizing and packing room, milk processing areas, and employee support areas such as a locker room, open office space, and a lunchroom. The project also included site development with a wastewater treatment facility, concrete and asphalt paving, landscaping, and associated sitework.
Suntado is the first vertically integrated class 1 and class 2 dairy processing plant in Idaho, able to process and package products in one location. The plant handles up to 1 million pounds of milk per day and produces a variety of dairy products, from extended shelf-life items to ultra-pasteurized, shelf-stable milk.

Suntado Dairy Processing Facility building

Burley, ID

Suntado Dairy Processing Facility

The DFA Cabool Plant expansion was an approximately 53,000-sf addition built on the west side of Cabool’s existing Automatic Batch Retort room (ABR room) to house a complete Glass Filling and Packaging line. Prior to the expansion, the Cabool Plant manufactured beverages in aluminum and steel cans for several U.S. companies. Construction of the addition included process filling lines, labeling and palletizing areas, packaging material storage, recycling docks, and material handling equipment charging area. The expansion also included various employee support areas such as break room, cafeteria, restrooms, as well as shipping offices, a trucker’s lounge, new truck scale, utility relocations, and additional parking for trailers.

Cabool, MO

Dairy Farmers of America Cabool Plant Expansion

Business Depot Ogden just got a bit sweeter with the completion of the new Hershey’s Distribution Center. Hershey’s is the nations second-largest candy maker. Due to the extreme heat sensitivity of chocolate, the Hershey’s Distribution Warehouse was constructed of an energy efficient steel frame building, insulated metal panels, a single-ply roofing membrane and an elaborate mechanical cooling system which is proprietary to Hershey’s.

Ogden, UT

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Pacific

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Hershey’s Distribution Facility

The DFA Quail Hollow Plant is a new construction, state-of-the-art milk drying facility and the first of its kind in the U.S. at the time of completion. Big-D’s project scope included construction of the 125,000-sf processing plant, a 4,000-sf wastewater treatment facility, and site development for the 31.5-acre plot. The facility includes areas for receiving, labs, silo alcoves, separating, wet processing, evaporating, drying, packaging, and warehouse space. Big-D self-performed the concrete work which included 40- to 60-ft high tilt-up wall panels for the process area, with the balance of the frame being structural steel clad with insulated metal panels. Deep pile concrete foundations support the dryer and evaporator towers. Finishes include insulated metal panel walls and ceilings, high performance wall coatings over concrete, urethane floor system and stainless-steel fixtures. Big-D coordinated deliveries and installation of all the building and process equipment. Challenges included heightened sanitation requirements and Big-D took numerous special precautions to avoid contaminates from the construction process from entering the new facility.

Fallon, NV

Big-D Southwest

Dairy Farmers of America Quail Hollow Milk Drying Plant

Aurora Organic Dairy’s Columbia, Missouri facility was a new construction dairy processing plant that includes processing areas, warehouse space, receiving bays and storage, truck scales, cold dock with trucker’s office and lounge, administrative offices, laboratory, a dry dock, a highly efficient wastewater pretreatment plant, and employee welfare areas. The plant also includes a 20,000-pallet refrigerated ASRS building with 17,250 vertical linear feet of auger cast piles supporting the foundation beneath the silo pads and ASRS areas. The new building was constructed with a single step installation process by using a steel frame with insulated metal wall panels to ensure efficiency and make them cost-effective. The floor finishes are scratch and stain-resistant epoxy and trowel down urethane concrete system coating, for the highest quality and durability.

Columbia, MO

Aurora Organic Dairy Columbia Milk Processing Facility

The Tyson Foods Case-Ready Plant is a new, 600,000-sf meat processing plant for fresh beef and pork. The facility allows for meat-cutting and packaging operations, where large cuts of beef and pork are converted into steaks, chops, roasts, and ground meat to be packaged, weighed, and labeled on retail trays for distribution to stores, “case ready.” The project, completed utilizing design-build delivery method, included construction of multiple structures; the Case-Ready Facility with processing, storage and office/administrative spaces, employee and truck security buildings, a storage building and a process waste pre-treatment building. The Tyson Case-Ready Plant is the first new facility of its type that Tyson has built in the past 20 years and at the time of completion was one of only four in the country and the first in the western United States.

Eagle Mountain, UT

Concrete

Tyson Foods Case Ready Plant

The Oatly Processing Plant project is an extensive tenant improvement renovation that converted an existing 135,000 square-foot industrial concrete tilt-up panel warehouse into a food processing/manufacturing plant for plant-based milk foods – specifically oat base and finished oat milk products. The main floor of the facility includes processing, assembly, warehouse, and shipping areas, as well as cold storage and warehouse space, offices and a research and development lab. The project scope included construction of a new 11,000 square-foot mezzanine that houses administrative spaces, employee locker rooms with dedicated clean entry, a large break room, conference room, IT storage, laundry, and process administration and electrical rooms. The facility establishes a higher standard for industrial food processing facilities by providing an appealing, modern, state-of-the-art facility for the people who work in the building. At the time of completion, this new Ogden processing facility was only the second Oatly facility of its kind in the United States and the first in the west.

Oatly Processing Facility

The United States Cold Storage project was comprised of an expansion and renovation to an existing cold storage warehouse and office building built in 2015. The addition added approximately 150,000 square-feet of freezer space and a 24,000 square-feet cold dock. The new freezer is a two-chamber freezer capable of operating at temperatures ranging from -10 to 34 degrees and the new receiving dock features 18 dock-height doors. The added space essentially doubled the capacity of the frozen food storage. The scope also called for additional semi-trailer parking, conversion of existing dry storage warehouse into a 40-degree cooler, and tenant improvements to the existing office/administrative areas. Office and administrative area renovations included construction of a receiving office, driver lounge, employee break room and a build out of the second-floor offices which included individual offices, open office space, conference room, training room, break room and restrooms.

Syracuse, UT

United States Cold Storage Renovation & Expansion

Food & Beverage Processing Projects

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