Case Study

Pet Food Company – Packing Hall

Case Study

Pet Food Company – Packing Hall

“Results from this created the additional head count efficiencies, met the food safety and pedestrian segregation objectives.”

The Pet Food company, specialising in high-margin pet treats, aimed to enhance efficiency and safety by centralising their packing operations. Overcoming challenges posed by varying floor levels with a GMP-compliant enclosed bridge, they successfully streamlined production flows, achieving operational efficiency, food safety, and pedestrian segregation goals.

Client Information

Pet Food company provides low volume, high margin niche specialty treats for cats and dogs. These nutritious treats come in multiple skus, shapes and sizes from different onsite manufacturing processes. The factory site contains separate manufacturing buildings and the company was looking to create a centralised packing hall to improve efficiencies, food safety and pedestrian safety.

Goal

The separate manufacturing buildings on site create high volume forklift traffic, moving finished goods between buildings. This created operational inefficiencies through double handling, food safety issues with external forklift transfers during inclement weather and pedestrian segregation issues between buildings. On top of this the site is split level with several metres between building floor levels.

Why TEG Projects

TEG engineers have a depth of experience managing building construction and process projects. The internal TEG processes for project management built over years of practice has led to the creation some of the most sophisticated checks and balances, including Risk Management, Tender matrix and detailed Cost Analysis to name a few. No construction project is too big or small.

Solution

Working with the onsite management team design brief and costing was engineered and submitted for business approval. An existing building nearest to the finished goods warehouse was selected to house the new packing hall. After relocating some racking and rationalising existing packing equipment to encourage efficiencies of operation, room was created to add new packing lines and transfer conveyors from the other production buildings.

Challenges

The different building floor levels created the biggest challenge, but with the design of an enclosed bridge engineered to GMP food safety standards, this obstacle was overcome. The existing production line outputs were funnelled through the new bridge along conveyors to the packing hall eliminating the external forklift traffic previously required. Working with operations and site food safety team, production targets were met with flexible engineering arrangements during the build.

Results

With all manufactured products funnelled to the new packing hall the site was able to streamline production flows from raw ingredients to finished goods warehousing. This created the additional head count efficiencies, met the food safety and pedestrian segregation objectives.

Capabilities

Pet Food Company – Packing Hall