The 41,000 sq. ft. Dry Goods addition for Hudsonville Ice Cream allows our client to keep dry ingredients on hand and point of use in lieu of shipping them in from off site. The addition was designed to address the owner’s current needs in the facility. The addition was constructed on the north side of the existing facility, offering 42 ft high dry storage with racking.
Spaces that Work Together: A shipping office, new IT room and truckers’ lounge were added. The added storage also houses a new CIP Room, cleaning and caustic product storage and bulk cleaners. Compactors for cardboard, trash and liquid were relocated inside to new area.
A new maintenance area space was created along with a parts mezzanine as well as a third level storage for electrical equipment and controls of compressors and refrigeration process control needs. Three air handling units and fans circulate air for ambient storage. The entire facility is set up with the new warehouse having the positive air pressure, therefore reducing contamination risk throughout the rest of the building.
Safety: Three (3) new vertical lift docks were added which keep the building margin tighter to trucks and the food delivery safer. Safety was increased for the truckers, eliminating the need to back up with an open truck. Now truck doors are opened by the owner once contact with the building is made.
Confined Schedule: In addition to a tight schedule Sept.. to Mid-March move, the entire project had to be sequenced the right way with key steps completed prior to other work. Steel framing, insulated metal panels, masonry bearing internal walls and precast flooring planks were used for the project. Winter conditions added a difficulty with masonry requirements. An existing rooftop condenser was moved by raising it but keeping existing freezer equipment operating.
Our team worked around the clock, taking down two condensers and connected one condenser initially to carry the temperature at -20 degrees. The COVID virus added difficulty of coordinating over 70 people involved in the project at that time, while some vendors and trade contractors were closed, and while implementing our on-site safe and sign in procedures.