Horse Cave, KY

T. Marzetti Company


Shambaugh & Son, L.P.


T. Marzetti Company

Services Provided

  • Automation Engineering
  • Electrical
  • Fabrication
  • Fire Protection
  • Mechanical
  • Process Controls
  • Refrigeration
Production equipment inside T. Marzetti's salad dressing line

Value Delivered

The project was completed on budget 25 days ahead of schedule.

Client Objectives

T. Marzetti Company was looking for a single source prime Design-Build services provider for their new, 220,000-square-foot state-of-the-art salad dressing facility in Horse Cave, Kentucky.

Scope of Services

Shambaugh performed a number of services including: mechanical, electrical, process control, fire protection, utilities, plant automation, tele-data, and security work. 3D modeling and an extensive amount of pre-fabrication were also utilized to accelerate the schedule, ensure quality control, and reduce costs.


  • Designed in 3D modeling software to allow customer to tour and evaluate the installation prior to construction services
  • 3D CAD was utilized to allow engineers and customers to improve plant and system ergonomics while also increasing fabrication opportunities for the purpose of accelerating on-site construction
  • Batch column technology was utilized for efficient ingredient addition
  • 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
  • Installed high efficiency fluorescent luminaries in lieu of HID in warehouses
  • Integrated Process Control/CIP Plant Automation system
  • Installed 55 miles of wiring
  • Installed 70 miles of piping and conduit

Client Background

The plant produces a wide variety of dressings and sauces. 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.