T. Marzetti Company
Design/Build Services
"2007 U.S. Food Plant of the Year"
The T. Marzetti Company selected Shambaugh & Son, L.P. as the single source prime Design/Build services provider for a new, 220,000 sq. ft. state-of-the-art salad dressing facility in Horse Cave, Kentucky. The plant includes diverse and efficient processes to provide present and future production capabilities for Marzetti's industry leading retail and food service products. The plant produces a wide variety of dressings and sauces. Marzetti's criteria for a qualified Design/Build services provider included a partner that had verifiable award winning credentials in designing and building innovative and efficient food process facilities. Shambaugh and Son were selected after an exhaustive six-month interview process. Shambaugh & Son self performed on a Design-Build basis mechanical services, electrical services, process control, fire protection, utilities, plant automation, tele-data, and security work with our own forces. 3D modeling and extensive amount of pre-fabrication was utilized to accelerate schedule, ensure quality control, and reduce costs. The project was completed on budget 25 days ahead of schedule. This project was selected as the 2007 U.S. Food Plant of the Year -- Shambaugh's 4th recognition for this coveted award!
"Shambaugh was selected based on its technical expertise in the food processing/manufacturing industry and for its track record of completing work on time and on budget" -- John Boylan, Treasurer, Lancaster Colony (parent company of T. Marzetti's).
Design/Build & Construction Services Project Highlights
- Designed in 3D model to allow customer to tour and evaluate the installation prior to construction services
- 3D CADD allows engineers and customers to improve plant and system ergonomics while also increasing fabrication opportunities which accelerate on-site construction
- Batch column technology for efficient ingredient addition
- Capable of producing several products simultaneously
- Totally automated bulk ingredient addition for maximum production capability
- Multiple state-of-the-art "reuse" CIP systems for fast effective cleaning to maximize production time
- Extensive use of product recovery systems to minimize valuable product loss while reducing high B.O.D. waste
- Receiving electrical power at 12,470 Volts. 8,000 amp service entrance at 480 Volts.
- Utilizing high efficiency fluorescent luminaries in lieu of HID in warehouses. Provides same lighting level at ½ of the power consumption
- Central dust control system in dry ingredient pre-blending area that reconditions and returns air that would normally be exhausted saving energy
- 1400 Ton secondary loop Refrigeration System reduced maintenance, energy, and first costs
- Integrated Process Control/CIP Plant Automation system
- 155 miles of wiring
- 70 miles of piping and conduit