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facility design
and construction
Our facility design & construction services deliver tailored solutions for food industry clients, guiding projects from concept to completion. With expertise in designing and building efficient, sustainable, and compliant facilities, we address every aspect of your project. Whether developing a new site, expanding an existing operation, or modernizing your facility, our team ensures your space is optimized for productivity and future growth. By integrating design and construction, we streamline processes, reduce risks, and provide cost-effective solutions that align with your operational goals.
project and capex planning
We partner with food industry clients to strategically plan and manage capital expenditure projects that align with business goals and budgets. Our team evaluates current facility needs, forecasts future production requirements, and prioritizes investments to optimize operations. From conceptual development to financial modeling, we ensure your project is on track for success. Our comprehensive approach provides the insights needed to make informed decisions, minimize risks, and maximize the return on your investment.
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We conduct facility audits to improve efficiency, safety, and compliance, providing actionable insights for optimizing production and supporting business goals.
facility audits
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We deliver feasibility studies for food industry projects, analyzing technical, financial, and market factors to create informed, actionable strategies.
feasibility / conceptual studies
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We design efficient, scalable facilities for food manufacturers, optimizing workflows, safety, and sustainability to support current and future growth.
master planning
project and capex planning
facility design and construction
manufacturing engineering
and integrationand construction
We provide comprehensive manufacturing engineering and integration services for the food industry, ensuring seamless coordination of systems and equipment. From conceptual design to full-scale implementation, our team specializes in creating efficient, automated workflows that optimize production and maintain product quality. With a focus on flexibility and scalability, we tailor solutions to meet current operational needs while preparing for future advancements.
consulting services
Our food manufacturing consultants offer tailored planning, design, and implementation services to optimize capital deployment, labor productivity, and system efficiency while minimizing waste. We align facility design with business goals to ensure successful, efficient operations in the food industry.
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Haskell optimizes systems with deep expertise across markets, leveraging the latest advancements in machine design and integration.
packaging systems
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We design and deliver advanced process systems for the food industry, enhancing competitive edge and meeting production goals
process systems
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We provide automated material handling solutions that enhance efficiency, reduce waste, and ensure food safety compliance in production processes.
Material/Ingredient Handling
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Haskell's refrigeration engineering group delivers sustainable, cost-effective solutions for industrial systems, specializing in design, refrigerant selection, and system coordination.
Cold Storage
and Refrigeration
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We deliver precise cost estimates for food industry projects, ensuring budgets align with needs, uncover savings, and support informed decisions.
project estimating
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We assist food manufacturers in site selection, evaluating suitability, risks, and resources to ensure optimal locations for facility development.
Site selection and due diligence
Our master planning services help food manufacturers develop efficient, flexible, and scalable facilities. We analyze your current operations, long-term goals, and industry-specific requirements to design layouts that enhance workflows, improve safety, and support expansion.
Whether you’re planning a new facility or upgrading an existing one, our team ensures your space is optimized for today’s production needs while being adaptable for future growth. With a focus on sustainability and operational efficiency, we deliver plans that set the foundation for success.
master planning
We conduct in-depth feasibility and conceptual studies to evaluate the potential and practicality of food industry projects. Our team examines technical requirements, financial implications, and operational considerations to help clients understand their options and make informed decisions.
By analyzing market trends, regulatory requirements, and process needs, we develop tailored strategies that address challenges and maximize opportunities. From initial ideas to actionable plans, our studies provide a clear roadmap for moving forward confidently with your project.
feasibility / conceptual studies
Our facility audits deliver a comprehensive assessment of your food production spaces, focusing on efficiency, safety, and compliance. We evaluate equipment, workflows, and infrastructure to identify inefficiencies, potential risks, and areas for improvement. With actionable recommendations, we help clients optimize production capacity, enhance product quality, and ensure regulatory compliance.
Whether you’re addressing existing challenges or preparing for future upgrades, our audits provide the insights needed to drive operational excellence and support your business objectives.
facility audits
We guide food manufacturers through the critical process of site selection and due diligence, ensuring every detail is accounted for. Our team evaluates potential sites based on utility access, zoning regulations, environmental conditions, and proximity to resources. We conduct thorough analyses to mitigate risks and support informed decision-making.
By providing a comprehensive understanding of site suitability and development potential, we help clients confidently choose locations that align with operational needs and project goals, setting the stage for successful facility development.
site selection and due diligence
Our project estimating services provide reliable cost projections tailored to the unique needs of food industry projects. We account for materials, labor, equipment, and market dynamics to deliver accurate budgets for new facilities, expansions, and upgrades. By identifying cost drivers and potential savings opportunities early in the planning process, we help clients make informed financial decisions.
Our detailed estimates ensure that projects stay on budget and align with long-term business objectives, providing a strong foundation for successful execution.
project estimating
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We renovate and customize food production spaces, modernizing workflows, ensuring compliance, and delivering efficient, tailored solutions with minimal disruption.
renovations and tenant improvements
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We design and build tailored facility expansions for food manufacturers, increasing capacity with minimal disruption, efficiency, and future-ready solutions.
facility expansions
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We upgrade utilities to boost efficiency, sustainability, and reliability in food facilities, ensuring compliance, durability, and minimal downtime.
infrastructure and utility upgrades
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We manage greenfield food facility projects, from site analysis to commissioning, ensuring efficient, sustainable, and future-ready manufacturing spaces.
greenfield development
We specialize in greenfield development projects for the food industry, transforming undeveloped sites into state-of-the-art manufacturing facilities. Our team manages every aspect of the process, from site analysis and design to construction and commissioning. With a focus on efficiency, sustainability, and compliance, we create facilities that meet production needs while being adaptable for future growth.
Our integrated approach ensures that your new facility is optimized for operations, reducing downtime, and delivering a streamlined path to full-scale production.
greenfield development
o Our facility expansion services help food manufacturers increase production capacity while maintaining seamless operations. Whether adding production lines, storage space, or employee areas, we design and construct expansions tailored to your needs. Our team works closely with clients to ensure minimal disruption to existing workflows, all while adhering to strict timelines and budgets.
By considering long-term growth, we deliver flexible, scalable solutions that enhance operational efficiency and align with your business objectives.
facility expansions
We provide comprehensive renovation and tenant improvement services to upgrade and customize food production spaces. From modernizing equipment layouts to optimizing workflows and ensuring compliance with industry standards, we deliver tailored solutions that meet your operational needs. Our team manages every step, including design, construction, and coordination with stakeholders, to minimize disruptions and achieve timely results.
Whether adapting an existing facility to new processes or repurposing a space for food production, we deliver functional, efficient environments.
renovations and
tenant improvement
We specialize in upgrading infrastructure and utilities to enhance the performance and reliability of food production facilities. From modernizing power and water systems to optimizing HVAC and process utilities, we deliver solutions that improve efficiency and support sustainability. Whether expanding capacity or replacing outdated systems, we ensure upgrades are executed with minimal downtime and maximum operational benefit.
Our focus on compliance, durability, and long-term flexibility ensures your facility is equipped to meet evolving production needs and regulatory requirements.
infrastructure and
utility upgrades
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Haskell's Industrial Water Team offers comprehensive wastewater management and reuse solutions
Industrial Water
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We design scalable warehouse solutions that optimize storage, improve efficiency, and ensure food safety compliance for dry, refrigerated, or frozen goods.
warehouse
and storage
Haskell’s refrigeration engineering group provides cost-effective and environmentally sustainable solutions for food industry clients. We specialize in packaged, central, and hybrid systems, working closely with clients to develop criteria for both brownfield and new industrial refrigeration systems.
Our team considers all design elements, including system requirements, refrigerant selection, component selection, system sizing and layout, control requirements, coordination with facilities and electrical, and more. We offer in-house expertise to meet all your refrigeration needs.
cold storage and refrigeration
Our dedicated Food Team develops tailored warehouse and storage solutions to meet the operational demands of food manufacturers. We design systems that optimize inventory flow, improve organization, and maximize storage efficiency for dry, refrigerated, or frozen goods. By incorporating advanced layouts and technology, we enhance accessibility and safeguard product quality while maintaining compliance with food safety standards.
Whether building new facilities or reconfiguring existing spaces, our team creates scalable, efficient solutions that seamlessly integrate with your supply chain operations.
Other services include:
warehouse and storage
Haskell’s Industrial Water Team provides wastewater management and water reuse solutions for clients in the food, beverage and consumer goods industries. Our services range from initial feasibility studies, conceptual design, and permitting through complete turn-key projects.
Our extensive experience in designing and constructing water and wastewater facilities allows us to provide thoughtful value engineering, constructability insights and operational awareness to bring the best value to our clients.
Other services include:
industrial water
Wastewater Pretreatment
Wastewater Systems
Incoming Water Systems
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We ensure seamless CQV processes, optimize performance, enhance efficiency, and maintain compliance for reliable, high-quality production operations.
Commissioning (CQV) & Line Performance
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Haskell’s Equipment Installation team provides expert solutions, ensuring high-quality execution, timely delivery, and minimal disruption with strict safety standards.
Equipment Procurement and installation
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Haskell delivers customized, turnkey automation solutions for the food industry, integrating automation, mechanical, and project management for efficient, low-maintenance operations.
automation
Our material and ingredient handling solutions are designed to streamline food production processes while maintaining product integrity. We design and implement systems for bulk material transfer, storage, and mixing to meet precise production requirements.
Our team focuses on maximizing efficiency, reducing waste, and ensuring compliance with food safety standards. From concept to installation, we deliver reliable, automated systems that keep your production line running smoothly.
Other services include:
Bulk Storage / Loading / Unloading
Mechanical & Pneumatic Conveyance
Dust Collection
Material/Ingredient handling
Storage Systems
Order Packing Systems
Conveyor Systems
Lift Truck & AGV Systems
Automated Storage & Retrieval Systems (ASRS)
At Haskell, designing and delivering advanced process systems tailored to client needs is a cornerstone of our facility solutions approach. Clients rely on us to develop systems that enhance their competitive edge in a demanding market. Our expertise in design, procurement, and implementation ensures process projects meet production targets and align with strategic goals.
Our engineering team specializes in creating automated systems for delivering dry, liquid, and mixed materials to high-speed packaging lines. These processes prioritize operator safety, minimize contamination risk, and reduce downtime between production and CIP, resulting in lower product losses and improved profitability.
Other services include:
Wet / Dry Ingredients
Fermentation / Pasteurization / Filtration
Blending (Batch & Continuous)
Extrusion / Co-Extrusion
Baking / Roasting / Frying / Cooking
Drying / Coating / Cooling / Freezing
Molding / Enrobing
Clean-in-Place (CIP)
Steam-in-Place (SIP)
process systems
Packaging-line design and development is a highly intricate process influenced by various performance factors, where even minor design changes can significantly affect capacity, throughput, accessibility, and efficiency. Haskell applies extensive expertise across multiple industries to create customized systems that meet our clients’ unique needs. Our designs integrate the latest advancements in packaging-line technology and system integration, driven by a clear understanding of both current and future requirements.
As trusted system integrators, we meticulously evaluate each project, selecting the best equipment to deliver flexible, innovative solutions. From conceptual planning to full facility execution, Haskell ensures superior performance and exceptional results.
Other services include:
packaging systems
Primary, Secondary, and Tertiary
Vertical Form Fill Sealing
Fillers / Seamers / Retorts
Flow Wrapping
Bag-In-Box Packaging
Display Case Packing
Palletizers and Wrappers
Robotics
Haskell offers customized, integrated automation systems tailored to the food market, utilizing state-of-the-art tools and industry best practices.
Our single-source solution delivers optimized performance and future-ready capabilities for food manufacturers, utilities, and process plants. By combining our automation, mechanical, and project management teams, we provide a turnkey approach that minimizes risks, adheres to tight schedules, and stays within budget.
Haskell's solutions are designed for ease of operation and maintenance, ensuring flexible and efficient systems that do not require constant engineering support.
Other services include:
automation
Control System Hardware
Programming (PLC / HMI)
Manufacturing Execution Systems (MES)
Industrial Internet of Things (IOT/IIOT)
Recipe Management / Batch Control
OEE Tracking
Traceability / Serialization
Vision Systems
Data Digitization & Capture
Haskell’s Equipment Installation team delivers comprehensive solutions to meet the diverse needs of our clients. From initial planning to final installation, our in-house experts specialize in delivering seamless equipment installation.
Whether it’s integrating new production lines, retrofitting existing systems, or managing the installation of large-scale equipment, our team ensures that every project is executed with precision. We coordinate closely with your team to ensure timely project delivery while minimizing operational disruptions, all while adhering to strict safety standards and best practices to guarantee long-lasting, efficient results.
equipment procurement and installation
Our experienced team meticulously oversees every stage of the CQV process, from initial commissioning to rigorous qualification and validation phases.
We ensure that all equipment and systems are installed correctly, operate as intended, and meet regulatory requirements. In addition to CQV, we focus on optimizing line performance, helping you achieve maximum efficiency, throughput, and product quality. Through detailed assessments, data analysis, and continuous monitoring, we identify areas for improvement and implement strategies to enhance production efficiency and reduce downtime.
Trust us to ensure that your facilities run smoothly and efficiently, delivering consistent results and peace of mind.
COMMISSIONING (CQV) AND LINE PERFORMANCE
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Haskell leverages advanced technology and system analytics to optimize production, simulate improvements, and enhance OEE without disrupting operations.
system analytics
Incorporating system analytics into your project provides many benefits such as helping you plan capital investments, improve production efficiency, or reducing startup and commissioning time through. Our system analytics offerings include simulations and emulations, master planning optimization, and system auditing and consulting.
With these insights, you can make informed decisions about expansion and new equipment and provide hands-on training before construction is complete.
system analytics
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We promote sustainability through innovative solutions, improving our operations, and supporting organizations that foster sustainable communities.
sustainability
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We conduct design peer reviews to ensure quality, efficiency, compliance, and risk reduction for successful food manufacturing projects.
Design
Peer Reviews
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We provide skilled engineers to support food manufacturing projects, filling expertise gaps and ensuring timely, budget-friendly project completion.
Engineering Staff Augmentation
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We provide expert consulting to optimize food processing, improve efficiency, enhance quality, and streamline operations while ensuring food safety compliance.
food processing consulting
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We ensure FDA/USDA compliance and GFSI certification with food safety-focused designs, supporting FSQA projects for reliable, long-term outcomes.
Food Safety Audits
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We optimize utility systems with tailored assessments, reducing costs, enhancing efficiency, and supporting sustainability for reliable food manufacturing operations.
Utility
Capacity Studies
Our utility studies provide in-depth assessments of energy, water, and utility systems to optimize efficiency and reduce operating costs. We analyze current consumption, identify areas for improvement, and develop tailored solutions to meet your facility’s operational needs.
From evaluating utility capacity for future production growth to identifying sustainability opportunities, we help food manufacturers ensure reliable, cost-effective utilities that align with their goals.
utility capacity studies
Our food safety audits provide an extensive evaluation of your facility’s processes, systems, and compliance with regulatory standards. We assess critical control points, sanitation practices, and equipment design to identify potential risks and recommend improvements. Our team works closely with you to implement tailored solutions that enhance food safety, ensure compliance with industry regulations, and protect product integrity.
Whether preparing for certification, addressing specific challenges, or maintaining high standards, our audits help safeguard your operations and build consumer trust.
food safety audits
We offer expert food processing consulting to help manufacturers improve efficiency, enhance product quality, and optimize production systems. Our team evaluates existing processes, identifies bottlenecks, and provides recommendations for implementing innovative technologies or workflow improvements.
Whether addressing challenges with production lines, packaging systems, or ingredient handling, we deliver actionable insights to streamline operations, increase throughput, and maintain compliance with food safety standards.
food processing consulting
Our engineering staff augmentation services provide skilled professionals to support your food manufacturing projects when you need additional expertise. Whether managing peak workloads, filling skill gaps, or accelerating project timelines, our experienced engineers integrate seamlessly with your team.
We offer flexible solutions to address short-term needs or long-term engagements, ensuring your projects stay on track and within budget.
Engineering Staff Augmentation
We perform thorough design peer reviews to ensure your food manufacturing projects meet the highest standards of quality, efficiency, and compliance. Our team evaluates designs for constructability, operational performance, and adherence to food safety regulations, providing recommendations to reduce risks and enhance project outcomes.
By identifying potential issues early in the process, we help you avoid costly revisions and deliver successful projects that meet your operational goals.
design peer reviews
Haskell has been committed to environmental sustainability in the AEC industry for decades, and this dedication will only grow. We focus on sustainability in three key ways:
1,) Leading by example through ongoing improvements to make our operations more sustainable.
2.) Leading with service by helping clients achieve their sustainability goals with innovative solutions for their facilities.
3.) Leading through support by actively engaging with organizations that create sustainable communities.
At Haskell, we create things that matter, and advancing sustainability is a vital part of that mission.
sustainability
manufacturing engineering and integration
consulting
Candy and Confections Safety Standards Matter
For candy and confectionary clients, Haskell delivers innovative design and construction solutions that enhance production capabilities while ensuring compliance with stringent food safety standards. We renovate facilities, expand them, and outfit them with state-of-the-art packaging machinery and streamlined operations while never sacrificing operational disruptions. For clients looking to make the world a little sweeter, we offer solutions that satisfy your project’s demands.
Pet Food
Quality Matters
Coffee Roasting and Processing
Business Expansion Matters
Haskell team members specialize in developing state-of-the-art roasting and coffee processing facilities that meet the growing demands of their brands, be it nationally or internationally. We provide comprehensive services, meeting the contemporaneous demands of our clients while carving room for business expansion in the future. Clients can trust Haskell for our deep expertise, collaborative approach, and proven track record in delivering successful coffee roasting operations that support long-term growth for a market beloved by millions all over the globe.
Baking
Innovative Design MatterS
Protein
Knowledgeable Partners Matter
Haskell not only partners with established clients who have been competing in their markets for decades—we assist producers in the protein space whether they’re launching a business from the ground up, or they have detailed, preestablished operational plans in place. With flexible services that can start as early as site selection and design concepts to equipment procurement and installation, Haskell has helped protein clients starting from scratch, as well as well-known and loved brands. When you partner with a company that has seen it all, you will know they can do it all.
Alternative Protein
Sustainable Practices matter
Haskell's Alternative Protein submarket is at the forefront of the shift towards sustainable and innovative protein sources. We provide end-to-end services that encompass market research, facility design, and production scalability, empowering clients to navigate this dynamic industry. With a focus on sustainability and efficiency, our expert team collaborates closely with clients to optimize their production processes while adhering to the highest safety and quality standards. For clients plunging into this market of the future, Haskell is ready to pave their way.
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Engineered a new production line and managed installation, earning top customer ratings for efficiency and on-site construction management.
Kelloggs Cheez-It Plant
Cheeze-It Plant
Case Study
The Cheez-It Capacity Expansion project involved designing a new production line from the oven discharge to the palletizer. The project scope covered a range of components, including a cooling conveyor, accumulation systems, scales, baggers, a cartoner, coder, tray packer, shrink wrapper, and material handling conveyor. On-site construction management was provided for the installation of all equipment and minor building modifications. A detailed startup plan was also developed, with the project contracted on a time-and-expense basis. The project was successfully completed on time and within budget in August 2016, earning an "A" on the customer report card.
facility for both bakery and distribution operations
24,000 SF
Project Highlights
• Project Management
• Construction Management
• Facility Design
• Mechanical & Electrical Design
Services
Cary, NC
Location
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Haskell completed a two-phase project, building a facility in under ten months and coordinating multiple shifts in an active plant, with concrete services critical to success.
Confidential Client
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Designed an advanced cooling system to improve air balancing and operator comfort at Blue Diamond's almond processing facility.
Blue Diamond Growers
Snack Foods
Production Capabilities Matter
Haskell delivers comprehensive solutions for the development, design, and construction of manufacturing facilities tailored to the unique needs of snack producers. Our services encompass everything from facility layout optimization to compliance with industry standards, ensuring efficient production processes. Haskell delivers efficient facilities so that producers can develop high-quality snack products that satisfy market demands.
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Integrated advanced packaging and production lines, ensuring FDA-compliant quality, sanitation, and safety standards.
Confidential Client
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A leading brand chose Haskell to design a new sandwich cookie line, overcoming budget and technical challenges to deliver an efficient, safe, and innovative production system.
Confidential Client
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Completed building expansion and relocation safely, with zero incidents over 150,000 manhours, maintaining full plant operations throughout.
Mars
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For 25+ years, Haskell has delivered facility expansions, line upgrades, and cold storage for Nestle Purina, providing innovative, reliable solutions for pet food production.
Nestle Purina
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Haskell built a 49,432-square-foot production and distribution facility for QuikTrip Bakery in Midlothian, TX. The $24.4M project included specialized storage, cold shipping docks, and process system startup for seamless operations.
Quiktrip Midlothian Bakery & Distribution Facility
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Haskell expanded a facility to produce 96 million pounds of coffee annually, integrating advanced systems for unloading, roasting, packaging, and palletizing, all under one roof.
Farmer brothers
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Haskell designed and built China’s first $175M roasting plant and distribution center, collaborating globally and overcoming challenges, including COVID-19, to deliver the project on time and to the highest standards.
Starbucks
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Haskell was tasked with converting a 60,000 SF facility into a plant-based meat production site, designing systems for ingredient weighing, blending, mixing, and automated packing processes.
Confidential Client
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For consumers who wholeheartedly invest in the life and diet of their pets, Haskell partners with pet food and treat producers positioned to satisfy market demand. Our services include facility design that prioritizes efficient processing and packaging, construction management to ensure compliance with stringent safety and quality regulations, and operational optimization to enhance productivity and reduce waste. Our deep understanding of the pet food industry’s demands—such as maintaining ingredient integrity and adhering to evolving regulatory standards—has positioned Haskell as a trusted partner for manufacturers serving this important consumer need.
Specialized in transforming production capabilities for baked goods manufacturers through innovative design and construction solutions, we focus on optimizing facility layouts and enhancing production lines, ensuring clients can meet rising consumer demand without sacrificing quality or safety. Known to innovative production lines with out-of-the-box, cross-market equipment design, Haskell’s ability to maintain product integrity makes us a trusted partner for clients looking to elevate their baking production while navigating the complexities of the industry.
Building Long-Term Client Partnerships and Operational Excellence
Case Study
At Haskell, we use our abilities to deliver on more than a client’s momentary needs—we form dynamic relationships to follow clients wherever they go, servicing whatever it is they need. Whether it’s production lines or a warehouse facility, we are moldable to the customer’s agenda, ready to add value to their business at any stage of development. Haskell’s history with this snack company is exemplary of just this philosophy.
This partnership has touched the lives of many Haskell team members, including CEO Jim O’Leary and COO JP Saenz, who managed the first of these facility projects back in 2010. Since then, Haskell has executed hundreds of projects across 15 different locations for the client, varying from designing and building warehouse expansions to EPC packaging and process work. Haskell played an integral role in helping to expand the client’s Geographic Enterprise System (GES) program, as well as their Automated Storage and Retrieval Systems (ASRS), across North America, finalizing many of these projects on aggressive schedules. Our office in Frisco, which we established to work on one of these snack projects in Texas, is living proof of our commitment to follow clients wherever they call us to.
Likewise, Haskell has been working on this project site in Connecticut since 2013. From a parking lot buildout to a 20,000 SF ASRS expansion, to an office renovation, this project is just another step in our journey toward providing flexible, on-demand services.
Our Longstanding Client-Builder Relationship
Every project Haskell embarks on is an opportunity to substantiate the trust clients invest in us, establishing partnerships and fulfilling Haskell’s core values of “Team” and “Trust.” By forming client relationships that extend beyond the lifespan of a single project, Haskell institutes the kind of reliability and expertise necessary for future re-engagement, exemplified by our 85% repeat client base. This is the exact story that led to our involvement on this snack project. When this major snacks manufacturer rolled out expansion and renovation plans for their largest and most expensive site to date, they determined that Haskell, their partner of over 15 years, was the natural choice for such a complex undertaking. As a result, Haskell not only provided the kind of design-build services a number of companies could offer, but also went above and beyond to extend the kind of customer service built up by years of successful joined ventures.
Building Long-Term Client Partnerships and Operational Excellence
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Existing Warehouse – Provided Structural Steel Reinforcement
72,000 SF
Rack Supported Automated Storage and Retrieval System Building
90,000 SF
Multi-Phased Projects
162,000 SF
Project Highlights
• Architecture
• Construction Management
• Process Engineering
Services
Confidential
Location
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optimizing
almond cooling
Case Study
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facility for both bakery and distribution operations
10,000 SF
Project Highlights
• Construction Management
• Facility Design
• Process Engineering
Services
Turlock, CA
Location
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Through Partnerships, We Achieve Solutions: Haskell's Successful Renovation and Expansion of a Candy Facility
Case Study
A part of a larger recapitalization initiative, this renovation and expansion project necessitated design, construction, expansion and engineering services. With disparate candy factories that were decades old and dotted all across the country, the client found that their constantly failing equipment was long past its beneficial use date. Their new project in Kansas had to include modern and state-of-the-art assembly and packaging machinery for peanut-free products, as well as the building space to install these capabilities. As a result of a pre-established relationship that had already delivered successful projects in the past, Haskell was enlisted early on, from concept negotiations through the Guaranteed Maximum Price (GMP) stage. Our role on this project as a truly integrated design, construction and engineering firm allowed us to consolidate our plans from the start, exercising decision-making power over the project to deliver innovative solutions efficiently, with no costs wasted towards doubling efforts Haskell can single-handedly do. After decisive collaboration internally and with the client, the project’s resulting scope included:
Project Scope
When the Haskell Company engages food-industry clients, we are not simply looking to deliver for them design or construction services—we are seeking to build abiding, trusting relationships. Our 85% repeat client base demonstrates this fact: Haskell builds “Partnerships That Matter.” It was through one such partnership that we came to design and build a candy facility for nearly half a million dollars. Our history with this client had begun six years prior with straightforward preconstruction and construction services, gradually evolving into more complex design-build projects, like a peanut roasting facility in Texas. When this client began plans for a confidential recapitalization project that demanded a credible and expert design-build partner, they thought immediately of Haskell. When clients have complex projects that take a varied problem-solving approach, Haskell is the name they associate with.
Through Partnerships, We Achieve Solutions: Haskell's Successful Renovation and Expansion of a Candy Facility
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Silo Building Addition to house new ingredient storage tanks
1,500 SF
Building Renovation including a new kitchen with process and packaging equipment
34,000 SF
Building Expansion for relocation of existing packaging equipment
68,000 SF
Distribution side includes dry storage, cooler storage, freezer storage, and cold shipping docks.
facility for both bakery and distribution operations
101,000 SF
Project Highlights
• Architecture
• Construction Management
• Design-Build
• Process Engineering
• Steel Fabrication
Services
Topeka, KS
Location
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A Sweet Success: Innovating Production For a Top Brand’s Sandwich Cookie Line Expansion
Case Study
As a part of this project’s original scope, Haskell designers, engineers, packagers and facility specialists were tasked with conceptually designing and master planning a bakery expansion that would produce cookies and other confectionary goods. Out of the four lines Haskell designed, three were typical cookie lines involving standard ovens, mixers, cookie cutters and molders. But one line was different: with a vision for a sandwich cookie line assembling cream-filled goods, the client was requesting a complex assembly line they had never installed before. With no reference or working model available, Haskell conceptualized and designed this unique system, which would enable the client to put a new product on the market and appreciate their company’s value.
While Haskell is always prepared to execute a clients’ loftiest ambitions, sometimes, the realities of budgeting directly interfere. When stakeholders of this confectionary project realized their monetary constraints, they knew sacrifices had to be made somewhere. Throughout the design process, Haskell maintained clear and consistent communication with the client, each and every design principal reporting to their respective counterpart so that when such a critical change had to be made, we were prepared to advise on the best course of action.
For Haskell, the challenge was this: how do we maximize the flexibility of our assembly line design so that it operates safely and minimizes labor, while simultaneously maintaining a budgetary fine line? Our conclusion: pushing only the third line—the sandwich cookie line—through to execution. While the standard cookie lines would have surely expanded the facility’s pre-existing output, the sandwich line would add totally new services and products to the client’s line. In our role as conceptual designer and master planner, Haskell did not merely provide drawings and documents, but worked with the client to maximize the value of both our services and assist in their product growth.
The Client Engages Haskell to Add Value to their Production Capacity
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facility for both bakery and distribution operations
283,000 SF
Project Highlights
• Construction Management
• Process Engineering
Services
Confidential
Location
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seamless delivery for peanut butter cup production
Case Study
When a client needed to install new equipment for a mini peanut butter cup production line, they trusted Haskell to deliver. Known for maintaining the highest standards of quality, sanitation, and safety, Haskell rigorously adhered to FDA food industry policies and ensured zero cross-contamination during construction. Using advanced BIM technology, Haskell enhanced design accuracy and constructability, further demonstrating their commitment to excellence.
Lorem ipsum
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• BIM/VDC Services
• Construction Management
• Design-Build
• Packaging Engineering
• Process Engineering
Services
Confidential
Location
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bakery & Distribution Operations
Case study
At Haskell, we are dedicated to developing innovative and efficient solutions that empower our clients to meet their consumers' needs. Our partnership with QuikTrip is a testament to our ability to provide scalable, cost-effective solutions that drive success in the competitive convenience food market.
Delivering Innovative Solutions for Today's Market Needs
Haskell's value extends beyond construction. We supported QuikTrip through every phase, from equipment procurement and installation to startup and commissioning. Our commitment included comprehensive training for QT’s operations staff, ensuring they were fully equipped to run the new lines efficiently. This project, completed in just over 10 months, marked our third successful collaboration with QuikTrip, underscoring our dedication to long-term partnerships.
Commitment Beyond Construction: Comprehensive Support and Training
What sets Haskell apart from the competition is our holistic approach and extensive experience in similar projects. Our integrated architecture, engineering, and construction teams collaborated closely to deliver a swift and efficient turnaround. We transformed a 50,000-square-foot space, enhancing both its interior and exterior with:
• A new bakery and bakery pick area
• Washroom and cool dock
• Cooler addition
• Office area
• Expanded employee parking and truck wash facilities
Our facility architecture and engineering teams meticulously laid out the new facility, ensuring seamless adaptation of process systems and support utilities for the new equipment. Beyond adding production lines for yeast and cake doughnuts, we delivered a turnkey solution for a new flour delivery system, showcasing our ability to provide end-to-end solutions.
Our Distinctive Edge: Collaborative Excellence and Comprehensive Solutions
At Haskell, we understand that our ideal customers, like QuikTrip, are focused on meeting rising consumer demands while minimizing costs and operational downtime. QuikTrip's biggest pain point was upgrading their production capacity swiftly to keep up with market demands. We addressed this by repurposing an existing distribution facility in Midlothian, Texas, and relocating their previous bakery operations from Coppell, Texas. Our expertise in brownfield EPC (Engineering, Procurement, and Construction) projects ensured a seamless transition, leveraging existing structures to save on capital investment and reduce lead times.
Transforming Challenges into Opportunities
In today's fast-paced world, convenience is key. As consumer demand for ready-to-eat foods continues to rise, QuikTrip faced the challenge of scaling up their bakery production efficiently and cost-effectively. They needed a partner who could transform their vision into reality without disrupting their ongoing operations.
Meeting the Growing Demand for Ready-to-Eat Convenience Foods
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Cold Dock Receiving and Shipping
38,000 SF
Cooler Storage/Pick Room
18,000 SF
Freezer Storage/Pick Room
16,000 SF
Distribution side includes dry storage, cooler storage, freezer storage, and cold shipping docks.
facility for both bakery and distribution operations
271,000 SF
Project Highlights
• Construction
• Engineer Procure Construct (EPC)
• Engineering
• Risk Management
Services
Midlothian, TX
Location
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Over 25 Years of Tailored Pet Food Solutions with Proven Innovation and Reliability
Case study
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• Construction Administration
• Facility Design
• Packaging Engineering
• Process Engineering
Services
Multiple
Location
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Rapid Response, Expert Recovery: Restoring Slim Jim Production After Disaster
Case Study
facility for both bakery and distribution operations
400,000 SF
Project Highlights
• Automation and Controls
• CIP Design
• Construction Management
• Facility Design
• Packaging Engineering
• Process Engineering
Services
Confidential
Location
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Confidential Plant-Based Protein Production Facility
Case Study
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dedicated to processing and packaging of plant-based protein burgers
18,000 SF
brownfield production facility to create plant-based protein products
60,000 SF
Project Highlights
• Construction Management
• Facility Design
• Packaging Engineering
• Process Engineering
• CIP Design, Automation & Controls
Services
Confidential
Location
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A Perfect Brew for
Global Expansion: How Haskell Helped Starbucks Build a Sustainable Future in China
Case Study
The onset of the COVID-19 pandemic involved unprecedented challenges, particularly during the design phase when in-person meetings were made impossible by strict travel bans. Haskell adapted to this new reality by shifting all interactions to virtual platforms. The team conducted virtual bid walks and inspections, utilizing on-site personnel equipped with headsets to project their surroundings through Microsoft Teams. Similarly, equipment Factory Acceptance Tests (FAT) were performed remotely, ensuring that quality standards were maintained despite physical distancing. Even when logistic issues arise, Haskell leaves no stone unturned in our quality assurance work.
Additionally, global shipping delays compounded the project's complexities. Haskell played a crucial role in coordinating customs paperwork and logistics, effectively acting as a liaison between the OEM and Starbucks. While stringent COVID restrictions and complex shipping regulations at Chinese ports inevitably resulted in delays, the situation could have been exacerbated had Haskell not taken on this voluntary support role. Ultimately, Haskell's adaptability and commitment to delivering results minimized the impact of unprecedented challenges wrought on the project timeline.
Project Challenge: COVID-19
What does it take to fuel the global expansion of one of the world’s most iconic coffee brands? For Starbucks, the answer lied in building a new roasting and distribution hub in Asia—one that would allow them to streamline costs, meet soaring demand, and open new doors for growth. Considering the scope and complexity of this project, Starbucks knew they would need to partner with an architecture, engineering and construction (AEC) company whose vision for the future was just as expansive. With over 21 offices, including international locations in the Asia-Pacific and Latin American regions, Haskell understands exactly what it takes to build a global brand and expand one’s market offerings. Burdened with the cost of overseas shipments and a taxed volume capacity back at home in the States, Starbucks engaged Haskell to design and build a new greenfield roasting site in China, whose scope also included an office buildout and the coordination of a third-party designed distribution center. Having partnered with us in the past and prioritizing our already established presence in the region, the client entrusted us to navigate challenges like the COVID-19 pandemic and international coordination to successfully deliver this project, valued at a total of $175MM.
A Perfect Brew for Global Expansion: How Haskell Helped Starbucks Build a Sustainable Future in China
facility for both bakery and distribution operations
600,000 SF
Project Highlights
• Facility Engineering
• Project Management
• Equipment Procurement
• Packaging & Process Engineering
Services
China
Location
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boosting brew capacity
Case Study
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Project Highlights
• Construction
• Engineer-Procure-Construct
• Manufacturing System Design & Integration
• Packaging Engineer
• Process Engineering
• Risk Management
Services
Northlake, TX
Location
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Design accounted for regular maintenance functions and safety
Robust Communication and Coordination: Weekly meetings and the use of 3D modeling facilitated clear communication between Haskell and the client.
Focus on Hygiene and Safety: The project prioritized food safety with features like closed-tube steel roofing, hygienic junctions for workers, and thorough planning to ensure zero recordable incidents during construction.
Value Engineering Success: Haskell proposed over twenty value engineering adjustments, resulting in cost savings of up to one million dollars.
Minimized Disruptions During Renovation: Strategic measures, such as installing temporary dust partitions, ensured that the facility maintained continuous operations.
Tunnel washer and rack washer equipment
Miscellaneous mixers, depositors, fryer, and ovens
Donut/baked goods line (sheeting, proofer, fryer, glazer)
Flour measuring and conveyance
Bakery equipment installed as EPC by Haskell includes:
Fully automated packaging system including grinding/shredding, mixing, batching, conveyance, forming, sealing, freezing and case packing
Multilevel access platforms, piping, pumps, valves, tanks, mixers, transfer panels and CIP system
Semi-automated process system
Client-Centric Problem Solving: Haskell went beyond the original scope by assisting with procurement and logistics coordination, demonstrating a commitment to customer service and proactive problem-solving that minimized project delays.
Sustainable Design Achievements: The Starbucks roasting facility in China earned LEED Platinum, 3-Star, and WELL certifications, showcasing Haskell's commitment to sustainability through innovative solutions.
Storage expansion to house the green and roasted beans
New systems designed to produce 96MM pounds of roasted coffee beans per year
Systems for roasting, flavoring, blending, batching, packaging and palletizing the final product
Multi-phased EPC
This snack project encompassed a total area of 162,000 SF divided into two phases. The first phase, which was completed in less than ten months, involved the construction of a 90,000 SF rack-supported ASRS building, as well as structural reinforcements for a pre-existing 72,000 SF warehouse. While the first phase was completed in less than ten months, the second phase required more meticulous planning, since work would be executed inside an active plant that would have to remain operational throughout.
Haskell's responsibilities in this $45 million project ranged from A/E design and construction project management to self-perform steel fabrication and concrete services. The project also included new trailer parking, a new receiving dock and an office remodel.
Project Scope and Responsibility
Given the extent and sheer scope of this project, the client engaged Haskell for our design-build capabilities, Fluor for their process and packaging services, and Dematic for material handling. Combining three distinct teams to work as one, seamless unit presented Haskell with challenges we were more than prepared to address.
The project team met once a week with the client, traveling to the site for periodic reviews as well. Besides these meetings, Haskell, Fluor, and Dematic held additional, weekly meetings, communicating amongst their designers, project managers, and even company executives. By engaging our companies at every level, this work became the effort of not only Haskell’s project management team, but of every Haskell team member all the way to the top. In this way, we were able to truly partner with Fluor and Dematic to ensure clear project coordination, with these three companies establishing a clear vision for how to serve our client as one, partnered unit.
This foundational network became crucial when coordinating with Fluor’s equipment installation team. While Haskell was completing the design and build of the expansion facility prior to its system tie-ins, there were certain elements that could not be completed beforehand. There were walls and utilities which, if placed too early, would block Fluor’s ability to install equipment, threatening to re-double work efforts and set the schedule back. Haskell’s designers and schedulers collaborated to determine the project’s sequencing and installation schedule, additionally coordinating with Fluor to clearly delineate the division of labor. As a result, the project proceeded in a timely and efficient manner without risking errors that would have cost the team time and energy to correct.
Haskell sought out further opportunities to boost project efficiency in the design-build scope of our work. As original equipment manufacturers (OEMs) had been pre-selected ahead of time, there was limited innovation possible for process design. We instead looked to the building that would envelope the equipment, as well as to the office renovation scope. By asking ourselves, “what does a facility really need to be clean and efficient,” we considered various construction methods, comparing insulated metal panels to tilt-up walls, contrasting rebar to fiber wall reinforcement. Even when certain value engineering options are not available to us, Haskell reviews every aspect of our building process to determine where efficiency can be maximized.
Haskell successfully navigated project delays during execution despite facing challenges from the COVID-19 pandemic and a complex permitting process. The global pandemic necessitated critical adjustments in our approach to design and permitting, which were carried out remotely. We also contended with sudden spikes in material costs, requiring us to secure prices and materials as quickly as possible. Understanding the lead time of equipment became crucial, prompting early purchases. Throughout this process, we maintained close communication with our vendors and scheduling department to mitigate potential delays.
Project Challenge: Collaboration and Efficiency
The permitting process posed its own unique set of challenges, particularly given the project's proximity to a lake-front private home association. Haskell engaged in extensive dialogues with the homeowner’s association for over a year, involving project leader in back-and-forth community negotiations. By persevering, and in an effort to deliver quality customer service, Haskell underscored our commitment to going the extra mile when navigating complex regulatory environments and community concerns.
Project Challenge: Mitigating Delays
Haskell demonstrated a rigorous commitment to safety in its management of this project, particularly through the proactive steps that ensured the well-being of all stakeholders, including factory workers and food safety. The team reduced potential hazards such as dust by carefully selecting materials, like cleanly designed steel and hangars, to meet stringent food safety standards. To prevent falls, a common risk in factory settings, Haskell installed ballasted handrails. Furthermore, the project’s construction phases were carefully planned to minimize disruption to ongoing operations, with specific measures like designated construction parking and access routes delineated to keep construction work operating safely, at a distance. Preplanning and optimal site utilization were key strategies, ensuring that all construction activities adhered to OSHA requirements and craftsmanship standards. Additionally, our design also complies with the Food Safety Modernization Act (FISMA), accommodating inspectors’ needs specific to this client’s operational standards. This comprehensive approach underscores Haskell’s dedication to maintaining high safety and quality standards.
Safety: Ensuring Compliance to Multiple Standards
Conclusion: Haskell Demonstrates Exceptional Adaptability
This snacks project showcases Haskell's adaptability, resilience, and commitment to our clients. Despite the challenges presented by the pandemic, collaboration with other firms, and complex project requirements, Haskell delivered the project efficiently to meet the client’s contemporaneous needs.
Partnerships like the one between Haskell and this national leader in snacks are invaluable. They allow for increased integration, coordination, and understanding, ultimately resulting in a more effective and efficient project execution. When awarded a project, Haskell does not view the work as a ‘one and done’ scenario—instead, we put in the effort to get to know our client, their current objectives, and their future outlook. In this way, our services suit large-scale clients across all industries, from salty snacks and beyond, to anyone looking for an AEC firm that invests in what they do.
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Rapidly mobilized a team to restore Slim Jim production after a devastating gas explosion, ensuring swift recovery to meet market demand.
ConAgra Slim Jim Facility
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With Haskell's expert guidance, a private equity firm built a state-of-the-art facility from scratch, now producing 450 million protein bars annually.
1440 Foods
From Concept to Completion: Powering 450 Million Protein Bars Annually with Haskell’s Expertise
Case study
This cold-form protein bar facility exemplifies a successful project delivery where extensive industry experience and client collaboration compensated for lack of specific process information. By reverse-engineering processes and adapting to the client's evolving needs, Haskell not only designed a functional and flexible manufacturing facility but also set the stage for future expansion and success. This project emphasizes the value of choosing experienced partners like Haskell in scenarios where clients may lack detailed manufacturing insights but are determined to achieve ambitious production goals. The outcome is a facility poised for long-term growth, proving that with the right expertise and collaboration, even the most complex challenges can lead to remarkable success.
Early Engagement Provides a Successful Delivery
However ambitious our clients’ goals are, Haskell is always prepared to fulfill them. When this private equity firm acquired a food brand producing protein snacks, they were venturing into an industry in which they had limited experience. The brand they purchased only came with a basic formula and product specifications—with no information on the process or manufacturing of their new product, this client was starting from the ground up. Faced with selecting a site, building a manufacturing facility there, and learning how to assemble their product, this client needed more than a design manager—they needed a real expert in food and snacks to set the project—and the client themselves—up for success. When Haskell agreed to be this client’s conceptual design manager, we were also agreeing to be their trusted partner and guide, equitably sharing risk. The result was a facility that could produce over 450 million protein bars a year, as well as a brand that was sure to succeed in the future.
Building from the Ground Up: How Haskell Helped a Private Equity Firm Break into the Protein Snack Industry with a State-of-the-Art Facility
Effective Communication and Trust: Haskell fostered a strong client relationship through regular meetings and transparent communication, ensuring alignment on project goals and risks, which was critical given this client had newly acquired their operation.
Tailored Facility Design: The design included nearly fully automated production lines, one high-volume and one flexible for varying bar sizes, along with a future-proofing strategy that incorporated stand-alone utilities for potential relocation.
Expert Collaboration: Haskell's deep expertise in food manufacturing enabled the reverse-engineering of production lines, addressing the client's lack of specific process knowledge and ensuring the facility was designed to produce 450 million protein bars annually.
Strategic Site Selection: Haskell advised the client through a meticulous site selection process, ultimately choosing an Indiana facility with existing food production infrastructure, which facilitated cost-effective operations and future growth.
Project Highlights
• Process Design Engineering
Services
St. Louis, MO
Location
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This project began with a site selection process, crucial for informing the design that was to come. After assisting the client in surveying everything from brown to greenfield sites, they eventually settled on an address in Indiana. After conducting site work on paper and in-person, Haskell encouraged this client to invest in the building they selected, as it had previously housed a separate food producer and still retained important features we could tie-in to the current operation’s needs. The existing infrastructure such as drainage and electrical capacity suited the new project's needs well, making it an ideal choice.
When electing this site, Haskell remained attentive to the client’s needs—the immediate ones, and those that would become pertinent in the future. Since this client had just recently acquired their new protein food brand, they were looking to satisfy consumer demand as soon as possible while also leaving space to grow and diversify their business. Accordingly, the client wanted to maximize investment in their equipment while minimizing investment in their facility, which was only being temporarily leased. By bringing in an in-house food safety manager who throughout the project’s lifespan, we identified ways to secure the building, protecting the food’s integrity while making minimal changes to the environment. Furthermore, Haskell designed all the food lines with stand-alone utilities so that one day, if the client wanted to move locations, their operations could easily move with them. The result was a state-of-the-art protein bar manufacturing facility designed to run production lines at full capacity while minimizing unnecessary costs.
The Advantage of Smart Site Selection
Working with a client green to food manufacturing, Haskell had to draw plans for a facility nobody was sure how to run. It was up to us to not only deliver drawings, but work hand-in-hand with the client, determining what the facility would need to produce 450 million cold-form protein bars, starting with bulk materials coming in and packaged goods going out.
This gap necessitated a unique approach where Haskell relied heavily on its food manufacturing experience to reverse-engineer the production lines. We engaged team members with extensive backgrounds in cold-form bars, who played a crucial role in designing the plant based on inferred needs and operational logic. This project presented a unique challenge, made possible by our extensive expertise as a fully integrated architecture, engineering, and construction firm, supported by subject matter experts with deep experience in the food market.
Working with the client’s project representative, Haskell conducted a volume and product assessment to understand and predict future growth. After verifying these findings from a supply-chain perspective, Haskell concluded that we could deliver two nearly fully automated production lines that would meet the client’s production goals while offering extra capacity. The first line is high-volume, while the second is a “flex line” capable of assembling three different-sized bars. Presently, we are also working on a powder blending platform, which will enable the client to break into a new sector of the protein-snack industry.
The Major Problem: Lack of Information
By value-engineering palletizer options, Haskell saved on infrastructure and environmental costs, freeing up capital for the client's operations. Identifying reputable original equipment manufacturers (OEMs) was crucial, as there was no existing equipment to reference. OEMs had to come with low risk and high reputations—Haskell eventually selected OEMs that are leaders in cold-form bars, and the packaging system acquired from them is touted as one of the best in the world. Haskell's strategic resource management, investment maximization, and expertise in sourcing high-quality equipment contribute to optimal facility performance.
None of these solutions would have been possible if Haskell had not first established a foundation of trust with the client. Effective communication was crucial, given the client's lack of a food manufacturing background. Regular, close interactions helped in aligning their expectations with the practical aspects of the manufacturing process, bridging the gap between non-technical input and our own technical execution. By meeting multiple times a week, we kept the client’s representative aware of the project’s risks, and only moved forward when all parties were in conscious agreement. Haskell’s belief in a transparent and open-book approach is what helped build a client-designer relationship that could surmount this project.
While Starbucks had previously engaged Haskell on a number of scaled projects across the U.S., the Starbucks China project represented a significant broadening of our service offerings, which we were well prepared to tailor to the client’s needs. Haskell launched this project from the ground up, designing the facility from its initial concept to schematic and detailed plans. Given China’s unique regulatory environment, Haskell was required to pass the remaining facilities design package to a local Chinese firm while the U.S Haskell team finalized process, packaging and automation design. While this was a rare situation for our design team who hadn’t previously worked with the Chinese state before, we were committed to working through whatever conditions our client needed us to meet.
Similarly, the construction scope available to Haskell was limited by both foreign administrative policies and travel restrictions linked to COVID-19. Instead of acting as a traditional Design-Builder, Haskell acted as a Construction Manager (CM) in the project’s execution phase, coordinating with our local team members to manage Chinese sub-contractors and ensure that the project proceeded according to plan. The breadth and diversity of Haskell’s team members meant that we could manage a variety of construction environments—there is always an expert on our side who knows how to get the work done.
Since this roasting facility and distribution center was a first for Starbucks China, it had to be done reliably and efficiently, to serve as a launching point for the company’s regional growth. This meant sustainability was a key priority, important to replenishing the client’s significant investment in the plant. Through the green solutions Haskell introduced, the project earned a LEED Platinum, 3-Star, and WELL accreditation, appealing to the highest environmental standards. Among these innovative ideas was a proposal to reuse the heat expended by roasting the coffee beans, which saved on the facility’s natural gas consumption and minimized emissions into the atmosphere. In combination with the plethora of solar panels installed on the roof, Haskell designed the Starbucks China facility to meet sustainable criterion while fabricating an efficient operation that would save both the client and the environment in the long run.
On the equipment side, Haskell managed extensive coordination with original equipment manufacturers (OEM), especially the principal OEM selected for this project, who became overburdened by its rigorous demands. This required Haskell to lead design management and perform significant modeling work, ensuring equipment was properly coordinated and cleared clash detection tests. The project’s scope also expanded mid-way when Starbucks decided to add a distribution center, requiring a complete redesign and additional coordination, which was further complicated by the virtual working environment during the pandemic. While procurement services were not a part of Haskell’s original scope of work, our willingness to go above and beyond helped resolve issues for the client that may have otherwise delayed the project. When we engage in work, Haskell is not merely bound by contractual agreements—we follow our unwavering dedication to customer service to deliver on a project’s true needs.
Project Scope: Delivering a Roasting Facility that Launches Starbucks into its Future in China
Despite the hurdles posed by COVID-19 and the inherent complexities of international communication, Haskell successfully managed the Starbucks China project, demonstrating flexibility, innovation, and a commitment to sustainability. The project not only satisfied Starbucks' supply and cost-saving needs, but also positioned them for future global expansion.
This project exemplifies Haskell's capability to handle large-scale, complex projects across different geographies and regulatory environments. Our services may appeal to global clients looking to expand their operational footprints, particularly those interested in leveraging Haskell's global presence and expertise in navigating both the logistical and regulatory landscapes efficiently alongside a multi-national, multi-talented team. This project underscores Haskell's ability to deliver comprehensive solutions that meet immediate client needs while setting their future trajectories up for success.
In Conclusion: Haskell Offers Comprehensive Solutions Anywhere in the World
Can multi-national teams achieve seamless collaboration when working from a variety of languages and locations across the world? Starbucks China posed this exact question, challenging Haskell to answer it. The project spanned multiple time zones, from the USA to China and Europe, creating a complex web of interactions. Language barriers and the technical nature of the discussions further meant that seamless communication would face some disruptions.
Haskell's APAC team, located in the same time zone as China, played a vital role in facilitating communication between Haskell U.S. and Starbucks China. Their ability to speak Mandarin was instrumental in bridging gaps and ensuring clarity, especially when coordinating discussions. While all parties communicated in English, it was not the first language for many team members across Europe, Malaysia and China. Our ability to navigate a plethora of languages and cultures ensured that the project’s details were conveyed accurately. This took dedication from Haskell’s team members in both the U.S and in APAC to transcend the roles and job descriptions they were used to fulfilling in their day-to-day work. For example, since, time zone differences posed significant hurdles, with a staggering 12 to 15-hour gap between the U.S. and China, team members often had to work outside of standard hours to connect with one another. By flipping their working hours and acting as translators and liaisons, our multi-talented team proved invaluable in coordination efforts. The proactive involvement of the APAC team helped streamline communication and ensure that all parties remained aligned, ultimately contributing to the successful progression of the project.
Project Challenge: Communication Barriers
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Building expansion which involved relocation of existing packaging equipment to allow space for new process & packaging equipment.
Building renovation implementing a new kitchen & process/packaging equipment. Our redesign of the area’s “Bay 2” involved installing new flooring, cooling tunnels, and makeup lines for candy bars, alongside relocating utilities and retrofitting the space to accommodate the non-nut line within the stringent hygienic standards required for food production.
Silo building addition to house new ingredient storage tanks.
Parking area for trucks and trailers.
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When working within pre-existing facilities, maintaining operations and minimizing disruptions is paramount to safeguarding client assets. For example, the new lines Haskell delivered work 24 hours a day and 7 days a week to produce 900 metric tons of candy each day—to shut down even a small part of this factory could have cost the client millions of dollars. Haskell implemented several strategic measures to avert such losses.
When one of the existing facility’s walls had to come down to make way for the packaging extension, we installed temporary dust partitions dozens of linear feet long. These walls were made of heavy-duty plastic and were fitted with insulated zip doors to ensure product safety and hygiene, preventing any contamination from construction activities while maintaining production continuity. While construction activities were happening on one side of the wall, on the other side, factory workers kept lines operational in secure conditions, negating disruptions to the client’s business while guaranteeing they’d reap all the benefits Haskell could provide.
Project Challenge: Keeping the Workspace Operational
Value engineering was a critical component of Haskell’s strategy to enhance the project’s cost-effectiveness without compromising on quality or functionality. Our design team collaborated closely with the client’s engineers to explore various cost-saving opportunities. Haskell did not propose one or two value engineering, but twenty. Prospective adjustments included site-casting tilt-up walls, reducing the building height, optimizing structural materials, revising window installations, re-wiring the mechanical and electrical work, relocating the storage silo building and much more. Herein lies the benefit of an integrated design-build firm with Haskell’s portfolio of experience. Diverse expertise comes together in Haskell’s drawing rooms as engineers and designers, safety managers and steel workers, collaborate to find where their disciplines meet and save the project money. On this project, these efforts led to substantial savings of up to a million dollars, underscoring our commitment to delivering value to our clients through a dynamic and united approach.
Haskell Leverages Value Engineering to Achieve Cost-Effective Quality
This candy project stands as a testament to Haskell’s ability to handle complex, large-scale industrial projects while ensuring client operations continue undisturbed. Our proactive engagement from the conceptual stage through to execution, combined with our focus on safety, innovation, and value engineering, ensured that we met and exceeded client expectations.
For businesses contemplating complex expansions or new constructions, especially in sectors where continuity of operations is critical, Haskell offers the expertise and experience to navigate these challenges successfully. We invite you to reach out and discuss how we can bring your project from vision to reality, ensuring operational efficiency, safety, and cost-effectiveness.
In Conclusion: Haskell Demonstrates Expertise in Managing Complex Industrial Projects
Throughout this project, our team maintained a robust communication line with the client, engaging in multiple calls each week from conception through to execution. This continuous dialogue ensured that all parties were aligned with the project's progress and expectations. Furthermore, we coordinated closely with the process installer, a crucial step to ensure the seamless operation of the facility upon activation, which had to go right the first time around. Organizing these efforts was challenging due to the larger size of the facility, so to overcome this, we held weekly coordination meetings. The use of 3D modeling played a critical role in these conversations, enabling us to effectively visualize and plan the integration of new installations within the existing structure. These efforts were essential for maintaining synchronization with ongoing operations, ensuring that the project advanced without disrupting the client's daily activities.
Ensuring safety while managing complex logistics in an operational facility required meticulous planning and execution. Although most open warehouse facilities use bar joists for their roofing structure, these are in fact dust magnets that threaten the quality of food products. Instead, our approach included closed-tube steel, concrete curbs, and resin floors, all of which facilitated easy cleaning and maintenance. Hygienic junctions were installed for workers to rid themselves of contaminants before engaging with the peanut-free lines, and the plastic partitions during construction operations kept the factory’s work area insulated from environmental pollutants. The efforts of Haskell’s in-house safety management team did not just safeguard the client’s production, but also maintained a secure construction environment for workers, resulting in a project with zero recordable incidents. By ensuring the integrity of the client’s food products and providing a secure working environment, Haskell enhances product quality and reduces the risk of accidents on every project we commit to.
Ensuring Safety and Efficiency in Coordinating Logistics
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For the baked goods industry, there is no greater disappointment that a consumer who fails to find their favorite cookie item on store shelves. Confectionary companies are laden with this responsibility: to continually innovate and optimize their production lines to satisfy and expand their base clientele. When embarking on facility construction, expansion, or renovations, these three priorities concern the industry: expenses paid when working with expensive and heavy machinery, narrow profit margins when selling relatively inexpensive products, and scheduling to accelerate their speed-to-market delivery. Haskell delivered on all three of these demands when engaged by a client requiring the addition of a unique sandwich cookie line to their existing operations. By partnering with Haskell, the client innovatively expanded their production capabilities to diversify their offerings and entice customers with fresh cream sandwich cookies. This case study highlights how Haskell master planned an expansion facility that emphasized quality, cost-efficiency, safety and a readiness for future food production challenges, all for a client creating some of the industry’s best-selling confectionary goods.
A Sweet Success: Innovating Production For a Top Brand’s Sandwich Cookie Line Expansion
Once we understood how central the sandwich cookie line would be in this bakery expansion project, Haskell’s project team deliberated on its design, manufacturing and tie-in. From a packaging standpoint, much of the equipment was complex. Having collaborated with a renowned equipment manufacturer from the Netherlands also meant that real-time communication and transcontinental design coordination would be difficult. It was up to Haskell to conduct a thorough investigation of the space beforehand, surveying existing utilities, water lines, underground sumps and more. Importantly, the original factory was kept operational all throughout this part of the project, so that we delivered accurate drawings that would keep the client’s business functional while simultaneously expanding and upgrading it.
While we thoroughly investigated the building’s infrastructural and environmental conditions, the sandwich cookie line had to be approached with equal delicacy. Two separate lines would be running parallel, eventually meeting in the middle to assemble the cookie and fill it with cream. The product had to run 400 linear feet from initiation to production, and in that time, anything could go wrong: the cream could melt or lose its integrity, or the whole cookie could fall apart. While deliberating on known original equipment manufacturers (OEMs), we realized that none of them offered the right equipment for such a fragile product. But our designers knew that to truly innovate, you have to forget everything you think you know about an industry and dare to think outside the box. Haskell eventually selected a cooling tunnel originally made for hard candies, but with some adjustments and upgrades to existing oven discharge belts, we perfected the environment the cookie would travel across, keeping the cream integral and controlling for moisture and temperature. Because Haskell’s design experts are so well versed in packaging and manufacturing rules, we also know when and how to break them, providing clients with one-of-a-kind solutions.
Our Innovative Approach to the Project’s Principal Challenge: The Cookie Cooling Tunnel
This project is not just a testament to Haskell’s ability to execute complex bakery line installations, but also highlights a common dilemma in the food production industry: balancing cost, efficiency and innovation. Many companies face similar challenges when expanding or modernizing their production capabilities within tight budgetary and operational constraints.
Haskell’s success in this project underscores our role as an ideal partner for companies looking to navigate the intricate landscape of industrial food production. We not only address, but also anticipate, our clients' needs, ensuring that each project is a step towards more efficient, safe, and innovative food production practices. As the industry continues to evolve, Haskell remains at the forefront, ready to tackle the challenges and opportunities that lie ahead.
Pioneering Efficient and Innovative Bakery Line Installations to Meet Consumer Demand
In confectionary work, safety is paramount on two ends: for those working in facilities, and for those purchasing goods produced by those facilities. Haskell assured that both these parties were protected by implementing various safety measures, like jacketing hot surfaces, installing motor lockouts, and ensuring all moving parts were adequately safeguarded to prevent operator injuries. Food safety protocols were rigorously followed by incorporating comprehensive Cleaning-in-Place (CIP) systems to maintain the highest standards of hygiene. And by controlling for the moisture and temperature of the cream cookies with our innovative cooling tunnel upgrade, we also assured the product would be developed in sanitary conditions. As trusted partners of the food industry, we prioritize both worker safety and superior product integrity to protect our clients’ brand reputation and quality.
Haskell Prioritizes Safety and Hygiene in Confectionary Production
When this client recognized a rising consumer demand for their cookie products, a crucial time window opened up for them to expand their supply. Recognizing the need for a quick project turnaround, scheduling was a crucial aspect of this project. Haskell completed the conceptual design and master plan of the facility expansion, including site investigations and equipment evaluation, well within a year. Cognizant of the client’s timeline, we re-routed equipment delivery, which would have taken six weeks by overseas shipping, to a more efficient method of airline transport. This decision highlighted our commitment to meeting the client's requirements while also showcasing our ability to evaluate and adapt the project plan according to the evolving needs.
Haskell Accelerates Project Timeline with Strategic Scheduling and Efficient Equipment Transport
Haskell's value engineering strategy started during the design phase with a clear focus on enhancing functionality while maintaining cost efficiency. Instead of purchasing new equipment, Haskell opted to repurpose existing machinery, considering alternative components like sprockets, belts, and flaps that could be easily swapped out. This approach not only resulted in significant cost savings but also accelerated the implementation process. By incorporating simple upgrades that avoided major expenses, Haskell effectively met operational goals without the need for entirely new installations.
Haskell Boosts Efficiency and Cuts Costs by Repurposing of Machinery
Commitment Beyond Design-Build
expertise
Building the Future of Food
Commitment to Safety and Compliance: Haskell implemented rigorous safety measures and ensured compliance with multiple standards, including OSHA and the Food Safety Modernization Act (FISMA), prioritizing the well-being of all stakeholders and minimizing disruption to ongoing operations.
Adaptability Amid Challenges: The project successfully navigated delays due to the COVID-19 pandemic and complex permitting processes, utilizing remote design adjustments, early procurement of materials, and proactive vendor communication to mitigate potential setbacks.
Collaborative Approach: Haskell partnered with Fluor and Dematic, establishing a seamless collaboration among all three teams through regular communication and coordinated efforts, ensuring efficient project execution and effective management of dependencies.
Long-Term Partnership: Haskell leveraged a 15-year relationship with a major snack manufacturer, reinforcing trust and reliability that led to being selected for a complex $45 million expansion and renovation project at their largest facility.
Nestle Purina chose Haskell for extensive capacity expansions at their Mechanicsburg, PA and Clinton, IA sites. Haskell handled civil/ structural work for new building additions to boost dry pet food production. The project aimed to create a "Two Bank Expansion" with upgraded processing, packaging, and infrastructure to support OEM equipment. This included enhancements in small and large batching, meal conveyance, grain grinding, liquids, coating, freezer, extrusion, and more. It also addressed mechanical ventilation, dry storage, parking, and a warehouse access road.
Capacity Expansion
Haskell was selected to provide facility engineering services and OEM equipment coordination for an expansion project aimed at increasing production capacity at the Dunkirk, NY facility. The project scope included installation of a new pet treat production line along with a milling system and mixing system. The major equipment included a hammermill, extruder, portioners, cooler, storeveyor, and a stand-up pouch line.
Dog Treats, Raw Materials + Full Production Expansions
Future-Ready Operations: The facility was not only built to meet current production demands but was also designed for scalability, positioning the client for long-term growth and diversification within the protein snack market.
Adaptability During COVID-19: Haskell navigated unprecedented challenges posed by the pandemic by shifting to virtual collaboration, utilizing technology for inspections and meetings, and maintaining quality assurance through remote Factory Acceptance Tests.
Effective Communication Across The World: Haskell navigated unprecedented challenges posed by the pandemic by shifting to virtual collaboration, utilizing technology for inspections and meetings, and maintaining quality assurance through remote Factory Acceptance Tests.
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Haskell has a long-standing relationship with a growing fast-food chain to design and build facilities for processing and distributing their food ingredients across several states.
Confidential Client
As the plant-based protein market continues to grow exponentially, more and more innovative companies are finding new ways to simulate meat products without affecting animals or environmental resources. But for a lot of these cutting-edge providers, scaling up production from a small lab to a facility capable of meeting high demand can be tricky. Haskell was contracted by a confidential client to accomplish this feat and help them launch its first large-scale processing facility.
We repurposed a 60,000-square-foot brownfield production facility to create plant-based protein products.
For this client, Haskell completed work on three greenfield plants, each over 100,000 square feet, along with several production expansion projects. Additionally, Haskell designed and built a wastewater pretreatment plant for one of these facilities, incorporating screening, equalization, chemical adjustment, and dissolved air flotation (DAF) units. One of these greenfield facilities was recognized with a 2019 Design-Build National Award of Merit from the DBIA, highlighting the quality and innovation of Haskell’s work.
Administrative Offices, Guard Shack, Trash
Enclosure, WWTP + Fire Pump Room
Warehouse Coolers, Warehouse Driver Area,
Warehouse Offices + Warehouse Space
Utility + Support Structures
Meat Receiving, Meat Processing + Meat Lab
Components for these greenfield projects included:
Our work for this client includes three greenfield plants as well as some production expansion work
300,000+ SF
Project Highlights
• Construction Management
• Facility Design
• Logistics and Distribution
• Packaging Engineering
• Process Engineering
Services
Multiple
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BUILDING PROCESS AND DISTRIBUTION CENTERS
TO GROW A CONFIDENTIAL FAST-FOOD CHAIN
Case Study
MIS + Store / Depot Maintenance Areas
With the new process and packaging lines up and running, Farmer Brothers is now able to provide additional production for its client accounts. As business continues to grow, we look forward to our continued partnership.
The new systems allow Farmer Brothers to better serve its customers.
Haskell undertook the redesign and construction execution of existing almond coolers in Turlock, California. The primary objectives were to enhance the cooling efficiency, reduce condensation and mold growth, and ensure regular maintenance and safety considerations. Haskell’s design expertise and efficient procurement and construction execution resulted in improved almond coolers that met the desired objectives.
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Scope included cooling conveyor, accumulation, scales, baggers, cartoner, coder, traypacker, shrink wrapper, material handling conveyor
Completed on time and on budget in August 2016
Construction management on site for installation of all equipment and minor building modifications
Detailed startup plan development
Contracted on a time and expense basis
Customer report card was an “A”
Designed and expedited procurement and construction execution
Existing almond coolers were redesigned to improve cooling and reduce condensation and mold growth
In order to keep costs lower, our client decided to purchase and convert an existing food processing facility rather than investing in a new greenfield solution. We have previous experience repurposing and consolidating existing facilities, which often includes evaluating which pieces of used equipment can be retained, updating the system layout, and relocating utilities and process piping to accommodate the new plan.
For this project, we utilized the engineering, procurement and construction (EPC) project delivery model, in which we designed the new process and packaging systems, procured all the necessary equipment, and performed startup and commissioning. The new semi-automated process system included a refrigerated product handling and packaging room with HEPA filtration and spiral freezing for the final product. We also added a Clean-in-Place (CIP) system that was right-sized for this plant to minimize wasted resources while providing the highest levels of food safety standards.
We also worked with the client to fully automate their packaging system, including steps for grinding/shredding, mixing, batching, conveyance, forming, sealing, freezing and case packing. This helped the client create a cleaner, safer environment for product preparation while also reducing the required manpower needed to operate the facility.
The completed facility helps the client meet the demands of a rapidly growing market.
With more consumers switching to plant-based proteins, our client continues to see rapid growth in product demand. But with a new, highly automated facility they are able to keep their products on the shelves and expand their flourishing customer base.
After relocating its primary coffee manufacturing from California to Texas, Farmer Brothers enlisted Haskell’s services for an engineering, procurement and construction (EPC) project to expand production at a new facility in the Dallas-Fort Worth area. The project was broken into multiple phases that began with master planning and design before moving into the actual project execution and startup. In all, this new expansion would increase the facility’s production capacity to produce 96 million pounds of roasted coffee per year.
Our master plan for consolidating Farmer Brothers’ roasting and packaging into one facility began with receiving areas for the raw materials, in this case, green coffee beans. From there, the process included equipment for unloading, cleaning, blending, roasting, grinding and flavoring the beans before sending them to packaging and palletizing the final product. Storage space was also planned and added to hold the beans prior to roasting. Additional handling systems to collect waste, such as the coffee bean chaff, were also included with the system, as was material-handling equipment designed to move 100 cases per minute from all packaging lines. Each phase was executed successfully, including the completion of startup and commissioning for all of the new systems.
We designed process and packaging systems to take our client from raw materials to packaged products.
Raw materials receiving for green coffee beans
Master planning services, technical expertise, engineering, procurement, construction, execution, startup and commissioning
New process and packaging lines
One of our greenfield facilities for this client received a 2019 Design-Build National Award of Merit from DBIA.
Haskell also designed and built a wastewater pretreatment plant for one of these facilities that included screening, equalization, chemical adjustment, and dissolved air filtration (DAF) units.
Existing building heavily damaged by natural gas explosion and Haskell had a team on site within 24 hours after explosion.
Haskell responded immediately when the only facility in the world producing Slim Jim products was heavily damaged by a natural gas explosion, with a team arriving on-site within 24 hours. Conagra urgently needed to convert the existing jerky processing area into a new Slim Jim packaging area to quickly return products to store shelves. Haskell took control of the site on June 10, and, through efficient project execution, Slim Jim production resumed just seven weeks later. Granted complete authority over the site, Haskell managed interactions with local, state, and federal agencies throughout the investigation process, ensuring swift and effective coordination.
90,000 man-hours, ZERO lost time accidents.
Conagra needed expedited conversion of existing jerky processing area into new Slim Jim packaging area to get product back on store shelves.
Haskell arrived on site June 10. Slim Jim production started seven weeks later.
Haskell was given complete control of the siteand authority for dealing with various local, state and federal agencies during investigations.
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ConAgra Slim Jim Facility
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Starbucks
Farmer brothers
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