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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 Beehive Cheese Plant is a three-man operation where they make specialty cheeses and curds. This plant consists of a 2,000 square-foot remodel of an existing metal building. The walls and ceilings are insulated metal panels and the floors are epoxy with a non-slip surface. A change out and upgrade of the mechanical, plumbing and electrical systems is required to support the change over of the building to a food-grade plant. The project includes milk receiving hook-ups, a production room, packaging production area, mold room, and a 34-degree cooler.

Uintah, UT

Big-D Southwest

Beehive Cheese Company

The Alta Dena Dairy Plant Expansion was a design-build delivery project that included multiple components.
The primary element was for construction of a new 34-degree cooler for additional milk storage. The cooler utilizes an ammonia refrigeration system and an in-floor conveyor for material handling. It was constructed with an eight-inch slab-on-grade foundation, steel tube framing, insulated metal wall panels, open web joists, joist girders, metal roof deck, and a single-ply membrane roof system. The expansion also included the addition of a new milk receiving bay, new door, installation of a silo tank pad foundation, and replacement of the fire protection system for the entire facility. Big-D constructed sitework and exterior project elements which included reconfiguration of the entire semi-trailer and auto parking throughout the facility, truck charging and site lighting upgrades, and a small amount of landscaping work.

The Alta Dena Dairy Plant Expansion was a design-build delivery project that included multiple components. The primary element was for construction of a new 34-degree cooler for additional milk storage. The cooler utilizes an ammonia refrigeration system and an in-floor conveyor for material handling. It was constructed with an eight-inch slab-on-grade foundation, steel tube framing, insulated metal wall panels, open web joists, joist girders, metal roof deck, and a single-ply membrane roof system. The expansion also included the addition of a new milk receiving bay, new door, installation of a silo tank pad foundation, and replacement of the fire protection system for the entire facility. Big-D constructed sitework and exterior project elements which included reconfiguration of the entire semi-trailer and auto parking throughout the facility, truck charging and site lighting upgrades, and a small amount of landscaping work.

City of Industry, CA

Alta Dena Dairy Plant Expansion

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

This project was for construction of a new manufacturing plant and warehouse/distribution center which was, at the time of construction, only the second Slim-Fast plant in the world.
The structure is comprised of site-cast concrete walls, structural steel columns and beams utilizing moment frame design, open-web steel joists, metal roof decks, and single ply TPO membrane roofing over polyisocyanurate board insulation. The plant layout includes product processing, filling and packaging areas, warehouse space, ammonia refrigeration system cooler, bulk receiving, administration and training areas. Interiors were built with dairy brick flooring and high-tech wall coatings in all process areas, shrinkage-compensating concrete floors with minimal joints in warehouse/distribution areas and surface-applied traprock coating. The cafeteria and corridors utilized ground-face concrete masonry units which enhanced the natural beauty of stone aggregates in the concrete. Work on the 85-acre site included a process wastewater equalization system, concrete roadways and parking area, utility coordination, preservation and relocation of native plants, and construction of perimeter fencing and hiking trails.

This project was for construction of a new manufacturing plant and warehouse/distribution center which was, at the time of construction, only the second Slim-Fast plant in the world. The structure is comprised of site-cast concrete walls, structural steel columns and beams utilizing moment frame design, open-web steel joists, metal roof decks, and single ply TPO membrane roofing over polyisocyanurate board insulation. The plant layout includes product processing, filling and packaging areas, warehouse space, ammonia refrigeration system cooler, bulk receiving, administration and training areas. Interiors were built with dairy brick flooring and high-tech wall coatings in all process areas, shrinkage-compensating concrete floors with minimal joints in warehouse/distribution areas and surface-applied traprock coating. The cafeteria and corridors utilized ground-face concrete masonry units which enhanced the natural beauty of stone aggregates in the concrete. Work on the 85-acre site included a process wastewater equalization system, concrete roadways and parking area, utility coordination, preservation and relocation of native plants, and construction of perimeter fencing and hiking trails.

Tucson, AZ

SlimFast Manufacturing and Distribution Facility

In 2017, Big-D began renovating a 25,000-sf warehouse facility for Bubbies in Phoenix, Arizona.
The scope of the project included a new quality control lab, a new bakery, processing, preparation, temper and packaging rooms (that are temperature controlled), new staff lockers and restrooms. This facility also includes existing freezers and coolers that were modified and brought to code during the renovation. The processing systems are fully automated so that now the ice cream is mixed and automatically dumped into the freezer, then frozen and pumped to the dough encrusters. From there, it is dusted before feeding onto the nitrogen freeze tunnel conveyor for final freezing, scanned and put into cartons and packaged for shipment.
The Bubbies project also includes exterior modifications including upsized electrical and water services, parking lot and fencing/gate upgrades. A second phase is anticipated to add a cold dock to the facility, closed loop chilled water system, site beautification package, site lighting, additional boilers, rice cookers, ice cream freezer machines, encrusters/dusters and a packaging automation system.

Phoenix, AZ

Bubbies Ice Cream Processing Facility

Big-D Construction built this new dairy processing and distribution facility in the late 1990s. Encompassing approximately 250,000-sf, at the time of construction completion, it was one of the largest dairy plants in the United States and incorporated state-of-the-art technologies. Forward thinking innovation included a palletless Automated Storage &amp; Retrieval System (AS/RS) which enabled significant reduction in labor in the cooler load-out area by as much as 50 percent and thereby decreasing operating costs. Completion of this project enabled Santee Dairies to be positioned as the “low-cost producer” within the dairy industry. In years to come, Santee Dairies would be acquired by Dean Foods and the plant is currently an Alta Dena facility.

Pacific

Santee Dairies Processing & Distribution Facility

This project was for construction of an addition to the Sun Street Ice Cream plant in Phoenix which included 32,000-sf of production space and lab, 57,000-sf of freezer room expansion and cold dock addition, and a novelty / ice cream plant. Construction consisted of concrete masonry block exterior walls, steel joist and metal deck, and concrete tilt-up freezer vault walls with insulated metal panel interiors, and durable, easily maintainable Spectra Glaze masonry and acid brick flooring. The new freezer and refrigerated spaces utilize a 900-ton ammonia cooling system, and the facility is powered by two 2,500 kVA transformers. Big-D’s scope included associated sitework for the development of their 10-acre site. All work was completed without interruption to ongoing operations, including mechanical and electrical system changeovers and required utility tie-ins.

Sun Street Ice Cream Plant Expansion

Swire Coca-Cola’s built a new 147,125-sf warehouse addition to the existing Swire Coca-Cola Glendale Distribution Facility. The site totals 270,950-sf over 8.5 acres. Project duration was 10 months; KDF Architects was the design partner on this project. Sitework included demolition of existing conditions, earthwork, SWPPP, new and relocated wet/dry utilities, drywell rework, site concrete, asphalt paving, pavement markings and signage, masonry fencing, stucco, landscaping. Building included demolition, concrete foundation and floor systems; tilt panel concrete exterior walls; structural steel roof joist and metal deck framing; roofing; skylights; exterior painting; interior insulated metal wall panels; (2) small restroom build-outs; doors, frames, hardware; overhead doors, chain link fence; dock equipment; Plumbing, Fire Protection, HVAC and Electrical systems; Fire Alarm.

&#8220;This team forges a strong general contractor/owner relationship through unquestioned integrity and transparency, clear communication and dedication to provide the best outcome possible for the owner.&#8221; Dan Reid, Senior Manager, Construction Management. Swire Coca-Cola, USA.

Glendale, AZ

Swire Coca-Cola Warehouse Expansion

Big-D started this design-build project by assisting the Owner to assess the viability of a new greenfield facility in the Las Vegas area. After months of due diligence, during which Big-D provided site analysis and detailed project cost models, Big-D was given the NTP for construction. The project includes three separate buildings: the main plant, a guardhouse, and a 10,746-sf vehicle maintenance facility (VMF). Attached to the VMF is a 3,000-sf ice cream freezer (for storage of product made elsewhere). The main building has approximately 17,000-sf of refrigerated warehouse. The scope of work also included a truck scale, administrative offices, enclosed milk receiving bays, and processing, packing, mechanical, and blow-mold areas. Finishes in the process areas consists of acid brick flooring and ceramic tile walls. Ceilings are walk-on IMP ceilings with interstitial utility spaces above. Sitework for this facility included off-site improvements and connection of utilities to the processing equipment.

Las Vegas, NV

Midwest

Mountain States

Meadow Gold Dairy Processing Facility

In 2007 and 2008, Big-D Construction completed a substantial overhaul of Malt-O-Meal’s Plant 3 in Tremonton, Utah. We  built an addition that housed a new office and truck shop as well as an addition for the plant’s Line 4 , which included a rail spur and bulk unload area.
The Line 4 addition is a 66,444-square foot, insulated, precast panel building with CMU masonry on interior partitions. The interior space in the addition is covered with epoxy paint in non-processing areas and painted with an FDA-approved Carbolene system in processing areas. The second-level grain cleaning area has exterior walls of structural steel with insulated metal wall panels. This addition included an addition to the docks with the building of two new dock doors.

Tremonton, UT

Malt-O-Meal Processing Facility

The Idaho Milk Products Jerome Plant is a new construction dairy processing plant for processing, packaging, and distribution of milk derivatives to locations around the world. It is a state-of-the-art manufacturing plant capable of processing more than three million pounds of milk per day. The structure consists of concrete tilt-up panel walls, steel framing, and insulated metal panel skin. Inside the building, spaces include not only the processing and receiving areas, but also warehouse space and an administrative support facility. Interior finishes include office finishes, dairy tile, insulated metal panel ceilings, and walls in process areas; sealed concrete walls and galvanized structural steel in the dryer towers; and epoxy-coated steel in other wet process areas.

Jerome, ID

Idaho Milk Products Processing Facility

Buckhead Meat &amp; Seafood is a new processing and distribution center for beef, poultry, seafood, and prepared foods. The building includes production space, cold storage and freezer, warehouse and distribution areas, office and administration space, a commercial kitchen, locker rooms, and employee welfare facilities. The production area has a 27-ft clear height and is conditioned and dehumidified with massive hygienic units. The production areas, view corridors, and access areas use “box-in-box” cooler construction with a 15-foot clear height insulated metal panel ceiling. The remaining areas use the full height of the structure with the facility envelope acting as the freezer/cooler insulation systems, complete with vapor barrier. Special systems included food testing labs, chemical wash, high-pressure wash, food-grade air systems, chillers (fed from ammonia plant), chilled water system, battery charge for handling equipment, ice melt area with heated floors and boiler water. Construction also included parking, landscaping, and extensive site utilities.

Houston, TX

Buckhead Meat & Seafood Processing of Houston

The Leprino Foods Lemoore West Plant was a ground up new construction project for a 750,000-sf, state-of-the-art dairy processing facility capable of processing six million pounds of milk daily into approximately 600,000 pounds of mozzarella cheese and value-added whey products. Big-D Construction’s scope of work included development of the 61-acre site that consisted of grading, site utilities, facility roads, and fencing, as well as an on-site process wastewater treatment plant and minimal off-site street development. The plant itself includes spaces for milk receiving, refrigeration engine rooms, cheese making and processing, cold storage, whey processing areas, a whey evaporator/dryer bin, a whey warehouse, offices, and storage. A unique feature of the facility is the utilidor, a two-story corridor throughout the plant housing all utility and process pipe main runs. The process areas feature a suspended walk-on ceiling constructed of insulated metal panels, directly accessible from the utilidor for maintenance from the second level.

dairy processing facility construction utah

Lemoore, CA

Leprino Foods Whey and Cheese Plant

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

Hershey’s Distribution Facility

Food & Beverage Processing Projects

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