PLAN-DESIGN-BUILD FOR THE FOOD INDUSTRY
We’re A Solution Looking For A Problem To Solve
Our Engineers have experience across a wide band of food processing industries, bringing innovative thought to each step of the process, from raw ingredients to finished packages. Dry, Vacuum, Wet, PMO Dairy… if it is food we can handle it. Check out some of our specialties.
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Our services include process consulting, plant design, project management and equipment installation to support:
- Production Line Install
- Product Optimization
- Product Recovery
- Clean-in-Place Evaluation, Design, or Upgrade
- Filling Lines
- Turnkey Solutions
- Industrial Refrigeration
- Wastewater Collection
- By-Product Utilization and Recovery
- Sanitary Process Development
Plan-Design-Build For The Food Industry
As the premier food processing design-build expert, DeJong Consulting has been called upon to design and build facilities for some of the largest food brands in America. Our teams have deep experience across business silos, allowing us to pull best practices from across the food and beverage industry to deliver innovative solutions to common problems.
We’re the company you need when food safety, profit margins, product innovation and production rates are of utmost importance.
Our in-house approach makes it easy to keep tabs on your project’s progress. A single point of accountability means that every answer is just a phone call away during the entire build cycle.
Our experience and nationwide team, allows us to handle a small portion of your project or the entire thing. From project management of your planned development to full food plant engineering, we are happy to play as large — or as small — of a role needed to help you reach your target.
We work with you to find process efficiencies and equipment improvements to elevate your plant to the next level. You’ll see your ROI increase, your plant production soar and the amount of waste you produce dwindle. We put clients first, no side deals with equipment vendors, no pushing products you don’t need. Just honest, creative problem-solving.
Contact us today to elevate your food production processes!
Dave Erlebach, Intrinsic Organics
I work with DeJong Consulting because of his industry knowledge, drive and willingness to go the extra mile. Many consultants would prolong the problem to make extra money, but Michael does what it takes to get it done.
We understand the challenges facing food manufacturers. From separating egg membrane, to cleaning the systems to transporting raw material throughout the facility, a food construction project is sure to have multiple challenges.
We work on a range of projects from very small retrofits to full facility construction.
Our experience allows us to see most problems before they arise and to propose solutions. From this, we are able to stay ahead of roadblocks, keep the supply chain running and ensure the project stays on track.
Whether you are expanding a production facility to meet consumer demands, adding cold storage capacity, or seeking to add a new plant location, our design and construction services can provide insight on meeting food safety regulations and keeping your food beverage industry project on track.
Refurbish vs Green-field Build
The primary considerations in green-field tend to be budget and timeline constraints. As a general rule, refurbishment can be a cheaper and shorter process – however, there are a lot more unknowns in a refurbishment. Additionally, layouts can be changed, but given that the bones of a building cannot be changed, a retrofit is rarely as space-efficient as a new design. The most impactful consideration, however, is often the physical location of the site in question. If supply chain constraints dictate, even the best ‘deal’ on a potential site for refurbishment may not be your best option.
As part of our consulting services, we regularly review and evaluate existing structures and potential build sites. We also are often involved with municipal and state agency discussions around incentivization, grants, funding, wastewater contracts, employer incentives, and similar planning-phase discussions. As part of that process, it is often a relevant question to evaluate specific sites in terms of short and long-term business impact.
DeJong Operations Management & Consulting has the experience and expertise to help you pick the right site the first time, whether your business needs a green-field build or a refurbishment of an existing site.
Meeting Stringent Hygienic and Regulatory Standards
Sanitary food plant construction is critical to ensuring the safety and quality of food products. Best practices in this area focus on creating a facility that meets stringent hygiene and regulatory standards while optimizing efficiency and sustainability. Here are some key best practices for sanitary food plant construction:
Compliance with Regulations:
Ensure strict compliance with local, national, and international food safety and building codes and regulations, such as those set by the FDA in the United States or equivalent agencies in other countries.
HACCP and GMP Principles:
Implement Hazard Analysis and Critical Control Points (HACCP) and Good Manufacturing Practices (GMP) principles in the facility’s design to prevent food safety hazards and ensure hygienic practices.
Zoning and Layout:
Design a clear zoning plan that separates different processing areas (e.g., raw material, production, packaging, and storage) to prevent cross-contamination. Optimize layouts for efficient workflow and sanitation.
Use food-grade, non-porous, and easy-to-clean materials for walls, floors, ceilings, and equipment. These materials should be resistant to corrosion and microbial growth.
Drainage and Sloping Floors:
Install sloped floors and efficient drainage systems to prevent water pooling and facilitate thorough cleaning.
Seamless Wall-Floor Joints:
Use coved base or similar designs for seamless transitions between walls and floors to prevent dirt and debris buildup in corners.
Sanitary Fixtures and Equipment:
Choose equipment with smooth surfaces, easy-to-clean designs, and minimal seams. Ensure equipment is made of food-grade stainless steel or other suitable materials.
Ventilation and Airflow:
Implement proper ventilation and air filtration systems to control dust, odors, and contaminants. Use HEPA filters and maintain a positive airflow to prevent contaminants from entering processing areas.
Ensure sufficient, cleanable, and shatter-resistant lighting throughout the facility to support proper inspection and cleaning.
Implement integrated pest management (IPM) strategies to prevent and control pests. Design the facility with barriers, screens, and entry points that deter pests.
Water Quality and Management:
Maintain high water quality standards for both production and sanitation. Use food-grade hoses and water management systems to prevent contamination.
Efficient Cleaning and Sanitation Systems:
Design sanitation systems, such as clean-in-place (CIP) systems, to thoroughly and efficiently clean equipment and processing areas.
Employee Training and Hygiene:
Educate employees about proper hygiene practices and provide facilities like wash stations and locker rooms to maintain high levels of cleanliness among staff.
Develop efficient waste management practices to handle and dispose of both solid and liquid waste in compliance with regulations.
Integrate eco-friendly and energy-efficient systems to reduce the facility’s environmental impact while maintaining food safety and product quality.
Regular Auditing and Maintenance:
Conduct routine audits and inspections to ensure that the facility remains compliant with food safety standards and regulations. Implement a robust maintenance program to address any issues promptly.
By following these best practices, sanitary food plant construction can help prevent foodborne illnesses, ensure product quality, and contribute to the overall success of the food processing operation.