Greenfield Plant Expansion

Salas O’Brien provided critical design and engineering services to develop a greenfield cheese plant for Hilmar Cheese Company, a leading dairy manufacturer. We performed extensive planning and cost estimation services. As the leading process integrator and design firm, we performed extensive work on wastewater treatment, complex plumbing, and the installation of various process equipment, tanks, and instrument controls. Our team also performed a comprehensive budget analysis for the electrical and process control plans. Our analysis aimed to identify major cost drivers and trends.

Process Engineering & Design
Our team completed the preliminary engineering and design for the plant’s wastewater treatment, which processes over 1 million gallons per day. The process instrumentation & controls systems we designed will minimize water use, optimizing energy usage and furthering the client’s commitment to achieve a net zero dairy industry by 2050. Water will be recycled and used throughout dairy processing to clean the facility and to reclaim waste heat. Our design encompassed the facility’s cold and hot water, process waste, natural gas, and compressed air piping systems.

Electrical and Process Controls Budget Analysis
We conducted a detailed review of the cost escalation for electrical and process control components. Our analysis focused on the differences between the 2021 and 2022 design estimates. Our team led the supply and installation of process Motor Control Centers (MCCs), Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), ASI enclosures, Control Panels, process electrical installation, controls programming, and startup support.

Challenges & Solutions
A primary challenge of the project was the significant cost escalation and extended material lead times across almost all divisions, driven by global supply chain issues and increased labor costs. The harsh winter conditions in Dodge City and the remote location further complicated logistics and labor mobilization. We addressed these challenges through strategic design modifications, including proactive recommendations for material procurement and storage. Additionally, the team faced an aggressive schedule and operational constraints. It was necessary to avoid delays, as downtime would have resulted in production being diverted to a competitor. To address this risk, we proactively established key project assumptions before final design confirmation, enabling the project team to advance engineering and construction activities simultaneously and keeping the project on schedule. We also faced the challenge of managing significant cost escalations and increased lead times driven by market conditions and scope changes. We actively identified each cost driver, pursued alternate pricing for different materials to reduce costs, and strategically procured vital equipment early in the process. Thanks to our expertise and agile solutions, the design process evolved continuously, resulting in a robust, functional new cheese plant.