Value Delivered
Shambaugh “fast-tracked” this construction services project and completed it five months ahead of schedule. In addition, Wonderware HMI software was utilized to integrate multiple PLCs for Pretzel’s process and packaging equipment. Thanks to Shambaugh’s design work, this plant was awarded the Food Plant of the Year award for “Fire Rebuild” projects, and Design-Build Institute Association National | DBIA Design-Build – Industrial Process Award.
Client Objectives
Wyandot, Inc. needed to update and expand their production facilities in Marion, OH after a fire did extensive damage to the plant.
Scope of Services
Shambaugh performed the pre-fabrication of platforms, material-handling
systems, piping and much of the plant’s infrastructure requirements. A total of 28 high-speed packaging machines and the largest fastback conveyor in the world were installed. We also designed sequential cooking/soaking systems, developed a low breakage corn transfer, and integrated their plant floor PLCs via Ethernet with their AS/400 system.
Our design work included many innovative features. We automated energy usage and inventory by product line, prefabricated and modularized packaging, weighing, and conveyor platforms, and designed product transfers that result in reduced changeover time and seasoning losses.
During the project, Shambaugh applied numerous “fast-track” construction methods, including:
- A sequenced construction schedule which allowed phased start-up of production lines
- Simulated production lines to expedite debugging and start up
- On-site design of key process components to support just-in-time engineering and construction
- Walking state and local construction permits through approval agencies
- Ordering steel for platforms and mezzanines before final design, then designing and fabricating around selected equipment
- A 7-day construction schedule, with two 10-hour shifts per day
- Large on-site crews peaking at nearly 300 people
- Prefabricated and prewired piping systems, control panels and air boxes to reduce site labor whenever possible
- Utilizing cable tray for electrical wiring to minimize cost and expedite installation for packing systems
Client Background
Wyandot, Inc. is a world-class manufacturer of snack food items.