September 23, 2021
Coming in at no. 67 is the 595,000-square-foot renovation of an existing distribution plant into a powder processing and warehouse facility for a leading nutraceutical powder blending company.
The newly renovated facility, which was completed in six phases over eight years, was designed to produce approximately 60 million pounds of finished goods at full buildout. In addition to the renovation, the project also added approximately 32,000 square feet to the building’s total area in order to accommodate and support a unique powder processes.
This facility, located in Aurora, Illinois, is comprised of: three-story blender pods, bulk raw material warehouse, ingredient warehouse, finished goods warehouse, QA lab, equipment washing and drying rooms, maintenance shop, 12 incoming and outgoing docks, boiler and chilled water mechanical room, offices, cafeteria, dust collection rooms, packaging and filling rooms, restrooms, locker rooms, uniform room, training room, ingredient weighing rooms, and battery charging area.
Significant effort was given to the evaluation and analysis of the entire manufacturing processes in order to design an effective facility with a focus on: efficient material and personal flows, minimizing non-value added labor, staff and food safety, and ease of future expansion with minimal operational disruption.