Wisconsin CheeseExpo 2024

WE ENGINEER SOLUTIONS TO COMPLEX CHALLENGES

CHEESE MANUFACTURING

EXPERTS

MANUFACTURING SOLUTIONS

CLEAN-IN-PLACE (CIP)

CONSTRUCTION MANAGEMENT

We deliver quality process + packaging solutions across multiple markets and materials. From greenfields to line upgrades or additions, our specialists are experienced in intgrating systems to function seamlessly and efficiently, providing cost + time savings to our clients.

In today's modern facilties, the Haskell team takes on the challenge to design and operate robust CIP systems in a more sustainable and effective manner. This includes systems that work better than previous designs and that use less water, chemicals, and energy and that send less effluent to the drain.

Haskell has many experienced design and construction professionals who will be assigned to the project. These individuals are long-term Haskell associates who has a depth and breadth of knowledge and experience in their respective areas of expertise.

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WHAT MAKES HASKELL UNIQUE?

With offices in Madison and Beloit, Wisconsin, we are committed to our dairy clients and understand the value of producing high-quality cheese. Haskell has a strong presence throughout the country and more importantly, we recognize the value of having strong local subcontractor relationships in Wisconsin.

Wisconsin Footprint

Haskell has a team of more than 800 facility, process, packaging and wastewater engineering professionals working side by side with our construction team members providing integrated design, design-build, preconstruction, construction management and general contracting services to the Cheese Processors.

Inhouse Design & Construction

One dedicated Haskell team works with each client for effective project coordination and communication. Your engineering partner is a key ingredient in delivering that product’s value promise to your customers.

ENGINEERING PARTNER

Our team's expertise in hygienic facility design, cheese processing and packaging lines, and wastewater-related projects ensures a seamless and efficient manufacturing process, no matter the style of cheese. Count on our dedicated team to deliver cost-effective design-build solutions tailored to your unique facility and processing needs.

UNDERSTANDING

PERFECTING OUR INDUSTRY EXPERIENCE

The project involved detailed design, programming documentation, validation protocols, and startup. It was divided into two phases: Phase 1 focused on NFDM and e-NFM Powder, and Phase 2 on Ribbon Cheese. A Master Integrator oversaw third-party electrical and software designs. Phase II programming included Front End Cheese, Starter, and Bulk Chemical. The Sweet Cream HTST cooling media was updated to Glycol from Ice Water, with local recirculation of Glycol. A plate heat exchanger Sweet Cream Pre-Cooler and PD booster pump were added. Phase II of the WPI Project focused on Back End Whey CC through ST, and Phase IC extension was for Solids Recovery. The WPI Retentate streaming was updated to relocate the Nanofilter in the process stream, update silo uses and destinations, and provide for new silos for Dryer feed. A new transfer line was provided for non-Condensed, pasteurized Phase I skim milk to supply 35% Retentate Silos in the Whey Department. Services were provided for the Conceptual Design of Whey Side Phase 2B Upgrades at the Greeley, CO facility. These upgrades processed skim milk through filtration equipment with the end purpose of drying the concentrate. On-Site Surveys were included to update drawings/documentation to an As-Built status. Services were also provided for the Detailed Design of Whey Side Phase 2B Upgrades.

Muller Quaker, a well-known client to Haskell as part of the PepsiCo family of brands, and Müller, a leader in the European yogurt market teamed up to produce a top-notch yogurt processing facility. The 363,030 SF plant was built on an 82 Acre Site in the Genesee Valley Agri-Business Park. The facility consists of a Front Office, Main Facility (which includes Milk Receiving, Milk Process, Yogurt Culture, Filling Hall, Packaging & Palletizing, Cooler Warehouse, and Ambient Warehouse), as well as a Guardhouse, 25MW Dual Feed Substation, Wastewater Pretreatment Plant and Fire Pump House.

MEET Your REGIONAL CONTACTS

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BOB PRICE

Design Director

GREGG SELIG

Director - Business Development

DAIRY INSIGHTS

Click on each of the below articles to learn more about our expertise.

Whey Processing: Basics of Cheesemaking’s Beneficial Byproduct

Methods to Achieve Sustainable Clean-In-Place

Addressing Frequently Asked Questions about CIP Systems

655 3rd St. Suite 203 Beloit, WI 53511

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DOWNLOAD OUR CIP DECK

JUAN CARLOS SALOM

Division Leader - Dairy

Your trusted resource for turnkey process, packaging + facility solutions.

The project involved converting a frozen cheese process into a 44-hour fresh shred cheese operation. This included the establishment of a new Starter area, Cheese Milk, and Sweet Cream HTSTs, along with DMCs. Installation support was a crucial part of the project, ensuring the successful implementation of the new processes. Additionally, the project also encompassed the re-design of the Indirect Water System, further enhancing the efficiency of the operation.

WE COVER A VARIETY OF MARKETS

FOOD

BEVERAGE

CONSUMER PRODUCTS

INDUSTRY PARTNERS

Expertise

- Material Receiving - Raw Material Handling - Wet Ingredient Processing - Dry Ingredient Processing - Rail Unloading - Dough Sheeting / Handling - Conveyor Systems - Automations Controls - Freezers / Ovens - Bag and Box Packaging - Palletizers & Wrappers - Finished Material Handling - Storage Solutions - Docks & Distribution - AIB Standards / Audits - Kit Assembly / Prep

Industry Partners

Project Spotlight

Relocation of Newark United Catering Kitchen to a new facility. New site was modified from a warehouse use facility to accommodate food production and catering needs. Emphasis on food safety, efficient production flow, and future capacity.

Food Experience

Beverage Experience

Industry Partners

Expertise

- Raw Product Receiving - Pasteurization - Cold Tank Storage - Mix Proof Valves - CIP/SIP Systems - ESL / Aseptic - Conveyor Systems - Automations Controls - Paper Carton Packaging - Blow Molding / Empty Bottle Handling - Bottle Filling - Case / Tray Packaging - Palletizers & Wrappers - Finished Material Handling - Storage Solutions - Docks & Distribution - USDA/FDA Regulations

Project Spotlight

Haskell provided design-build project delivery to construct a 1MM+ SF facility to bottle, store, and distribute Coca-Cola products. A total of six buildings were erected on 140 acres, allowing the client to replace several smaller aging plants with one large, new facility built with room to grow.

Consumer Products Experience

Industry Partners

Expertise

- Material Receiving - Raw Material Handling - Wet Ingredient Processing - Dry Ingredient Processing - Rail Unloading - Conveyor Systems - Automations Controls - Bag and Box Packaging - Palletizers & Wrappers - Finished Material Handling - Storage Solutions - Docks & Distribution - AIB Standards / Audits - Case / Tray Packaging

Project Spotlight

As Nike planned to combine operations of two existing facilities into one new greenfield Memphis, Tennessee, distribution facility, they also took the opportunity to make an environmentally-friendly statement. They turned to Haskell for a master plan for the 125-acre site, which would provide parcels for a future pallet storage warehouse, a distribution warehouse and another branded footwear line.

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Rick Elyar

Director - Business Development

PETER HALL

VP - Process Services

WE TAKE FOOD SAFETY SERIOUSLY

Don't make food safety an afterthought. The layout and design of your food processing facility must be adapted to the hygienic requirements of a given process, packaging or storage area.

1. Email your food safety question to FoodSafety@Haskell.com 2. If related to active project, specify project name 3. Food Safety team will respond as promptly as possible (target < 24 hours)

HOW DOES IT WORK?

- Food Safety Consulting - Identify Hygienic Zones of Risk & Separation - Manage Circulation Paths (Product, Waste, People) - Controlled Hygienic Entry Points - Climate Controls & Air Pressurization - Walk-on Ceilings - Interstitial Space for Utilities - Sanitation Standoffs From Wall & Ceiling - Drains, Curbs & Equipment Footings - Control Water Accumulation

BEST PRACTICES

MEET OUR FOOD SAFETY EXPERT

GREG JANZOW

Food Safety Director

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5325 Wall St. Suite 1700 Madison, WI 53718

BOOTH #1880

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MANUFACTURING SOLUTIONS

CLEAN-IN-PLACE (CIP)

CONSTRUCTION MANAGEMENT

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“Food safety is one of the first conversations we have with clients because protecting your brand begins with a proactive approach to design to mitigate the risks of cross contamination.” – GREG JANZOW , DIRECTOR OF FOOD SAFETY

WE TAKE FOOD SAFETY SERIOUSLY

Don't make food safety an afterthought. The layout and design of your food processing facility must be adapted to the hygienic requirements of a given process, packaging or storage area.

BEST PRACTICES

April 16-18 | Milwaukee, WI

RICK ELYAR

Director - Business Development

MANUFACTURING

Manufacturing Experience

Industry Partners

Expertise

Project Spotlight

The facility includes: two-story administrative offices, Clean/Dry rooms Class 1,000 (ISOC Class 6), certified with - 40C and -27C return dew points, coating ovens, formation area (charging) and open circuit voltage (OCV) testing area, final manufacturing/assembly area, electrical, chillers and air compressor rooms, maintenance and support areas, and shipping and receiving docks.

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Trusted resource for turnkey process, packaging + facility solutions.

CHEESE MANUFACTURING

EXPERTS

BOOTH #1880

CONFIDENTIAL CLIENT

CONFIDENTIAL CLIENT (MULTIPLE PROJECTS)

The project involved a preliminary study on String Line Renovation, along with the documentation for Zero Tolerance. It also included the Process Detail Design and Control System Engineering for String Cheese. The programming documentation and project coordination were integral parts of this project.

The project involved the integration of Pre-Heat Tank #3 into Line 2 Cheese Line. A plant survey was conducted to develop as-installed Process and Instrumentation Diagrams (P&IDs) for several components. These components included Line 1 and Line 2 Fines Savers, the Fines Heater, and the Line 2 Whey Heat Treatment Unit. The Line 2 Whey Heat Treatment Unit also had Hot and Chilled Water Loops. Additionally, updates were made to the WMOL/fines savers modifications as part of the project.

The project encompassed several key stages. It began with the Detail Design, followed by the Programming phase. Project Coordination and Installation Observation were integral parts of the process, ensuring that all elements were correctly implemented. The final stage was the Start-Up, marking the commencement of the project’s operation.

The Cheese Freezer CIP Upgrade project involved several key steps. The design of the new CIP spray ball requirements was undertaken, which included fixed stainless steel sprays with slip pins. The sprays for the overall enclosure were modeled to simulate coverage. The capabilities of the existing CIP system were confirmed to handle the new cleaning requirements. Any new pumps and valves were sized appropriately. Lastly, it was ensured that the CIP spray design was compliant with USDA and California dairy regulations.

April 16-18 | Milwaukee, WI