Manufacturing and Food Processing

The bulk of this project consisted of replacing the existing roller mills (1950s vintage) with new roller mills, condense from 19 stands on 2 floors to 15 stands on 1 floor. This made access to the mills to change the rolls easier because everything is now accessible with a cart on the first floor vs. needing to use a forklift to get rolls to the second floor as in the past. Though we decreased the number of mills, we increased the output. We also replaced auxiliary equipment (dusters and scales).

In addition, we added a control room, painted walls and ceilings, epoxy coated the floors, installed new lighting with occupancy sensors, as well as updated the mill controls. We did all this using electrical and process design. This entire project was done in a very small footprint with low headroom.

Reader’s Digest Expansion – $70 million expansion including a 250,000 sq. ft. addition for printing of all Reader’s Digest magazines in the U.S.; Installation of three new presses, two patent binding lines, and five mail lines.

Gravure Expansion – Complete engineering design for 135,000 sq. ft. plant expansion to accommodate new gravure presses, associated spaces, and specialized solvent recovery system.

Roll Storage Addition – Design of a 63,000 sq. ft. roll storage addition to existing printing plant including a 50,000 sq. ft. Early Suppression/Fast Response fire protection sprinkler system.

Press Area Upgrade – Renovations for the addition of three printing presses; four 40′ x 50′ roof bays were raised to create penthouses for press equipment.

Additional Projects – Chiller addition and redesign of chilled water piping system for entire facility; Spot cooling for printing press operation; Pressroom air conditioning upgrades at Financial Printing Division plant.

Facility Expansion – Full-service engineering services for a 121,000 sq. ft. state-of-the-art manufacturing plant expansion constructed in three phases. The first phase included consolidation and relocation of assembly lines into the expanded facility, allowing for all motorcycle models to be assembled in one building. The second phase entailed a 28,850 sq. ft. two-story addition. The first floor houses warehouse space, new outdoor patios, a meeting room, and renovations to the existing cafeteria, while the partial second floor contains office spaces. The final phase was 21,775 sq. ft. and includes a new fitness area, physical therapy center, retail shop, tour center, and a theater.

Softtail Manufacturing Plant – Development of equipment layout schemes and process utility design for new 350,000 sq. ft. manufacturing plant. Equipment was both new and relocated from adjacent facility.

Open End Contract – Multi-year contract at the one million square foot Harley-Davidson Final Assembly Plant in York, PA. Several hundred work orders have been received, including survey of existing 115KV and 13.8KV electrical system, development of one-line diagrams, survey of existing 480-volt distribution system and verification of all associated equipment, study and design of improvements to compressed air system, design of industrial wastewater pumping system and piping, development of plant standard specifications, telecommunication surveys, rebalancing of assembly line, various heating and ventilation studies, and more.

Paint Building – Major new state-of-the-art paint spray facility for applying finish to motorcycle parts, and subsequent addition. For the latter project we also supplied an on-site resident representative during construction of the 10,000 sq. ft. Project.

Heat Treat – Relocation/installation of existing Heat Treatment equipment used in the production of motorcycles.

Next Century Expansion – Full-service engineering for a 360,000
square foot expansion of the Hershey West Plant for production of
Hershey Snack Bars, Hershey Kisses, Rolos, and Hershey’s Syrup. The
facility was designed in Revit to create a comprehensive Building
Information Model (BIM).

Administration Building Modernization – Full-service engineering for Administrative Building renovations at the Mack headquarters. The project drivers were the need to expand the facility while updating the existing building to modernize the spaces and conform to branding standards. The scope included infill of an existing courtyard to create 2400 sq. ft. of new space as well as renovation of the two- story, 24,000 sq. ft. existing building. In addition, 18,000 sq. ft. of space in the adjacent manufacturing building was renovated to accommodate conference rooms, training rooms, and a new cafeteria and kitchen. An additional 13,000 sq. ft. of office space was created above the cafeteria.

New 77,000 sq. ft. printing facility attached to newspaper headquarters building. Mechanical, electrical, plumbing, fire protection, and process engineering was provided to the new facility, which houses a KBA Colora offset printing press, packaging and distribution, mail room, ink storage, reel room, and computer-to-plate room.

Corporate Headquarters Relocation – Engineering in support of a 260,000 sq. ft. project to create the North American Headquarters for this manufacturer of firearms for military and police. The scope entailed renovations to an existing building to create Class A private and open offices, executive suite, conference rooms, two-story foyer/lobby, product display room, training rooms, cafeteria, and fitness room. The project also entailed renovations to accommodate manufacturing and warehousing space.

Corporate Headquarters – Engineering services for a 32,000 sq. ft., two-story addition to the headquarters building.

Corporate Headquarters Expansion – Engineering in support of design-build project for 32,000 sq. ft. two-story addition to the corporate headquarters including private offices, open offices, employee lunchroom, connecting space, and courtyard.

Hot Chaff – Expansion of the existing 350,000 sq. ft. Building 3000. Work included phased construction for demolition, temporary conveyor modifications, and building shell addition in preparation for upgrades to the roasting hot-chaff transport and delivery system.

Plant Air Conditioning – Major project to add air conditioning to the existing 350,000 sq. ft. York Roasting Plant Building 3000. Air conditining system consisted of fourteen packaged rooftop units totaling 560-tons of cooling capacity. The packaged rooftop units are located on five structural steel roof platforms, each spanning between existing columns. Structural steel was extended up through the roof at the columns to support the steel platforms.