Pizza Plant Expansion

Problem

The manufacturer needed to scale production with an efficient system that increased throughput while ensuring quality and compliance with strict food safety standards. 

• Capacity Expansion: The facility needed to accommodate new production lines and equipment, expanding from 23 million to 30 million pizzas annually. 

• Scope Evolution: Multiple scope adjustments occurred, including changing equipment specifications, adapting production line designs, and integrating additional utility systems. 

• Vendor Coordination: Equipment vendor delays and design revisions required agile management to maintain project momentum. 

• Infrastructure Complexity: Upgrades to refrigeration systems, utility capacities, and compliance with ammonia safety standards were critical. 

Solution

Sharpe Engineering provided end-to-end project management, engineering design, procurement, and vendor coordination to ensure seamless execution. 

• Phased Implementation:

1. Office expansion and new electric/refrigeration engine rooms. 

2. Plant expansion and installation of Line 2. 

3. Reconfiguration of Line 1 and addition of a new holding freezer. 

4. Installation of Line 3. 

• Equipment and Process Layouts: Detailed layouts ensured optimal workflow for production and personnel, accounting for sanitary and operational requirements. 

• Production and Equipment Specifications: Developing precise specifications for ingredient preparation, assembly, packaging, and material handling processes. 

• Utility and Infrastructure Upgrades: Expanding refrigeration capacity with a transition to ammonia-based systems, upgrading compressed air, and increasing electrical loads. 

• Project Management: Budgeting, scheduling, and vendor coordination, including RFP management and bid evaluations. 

Engineering Solutions 

• Dynamic Scheduling and Coordination: Sharpe Engineering mitigated delays by maintaining close collaboration with vendors and contractors, reworking schedules, and maintaining open communication with the project team.

• Enhanced Design Features: Redesigned production lines to achieve 80% line efficiency with capacity for future growth. 

• Compliance Leadership: Ensured adherence to OSHA and EPA standards for ammonia refrigeration systems through safety and management protocols. 

• Tailored Layouts: Created phased installation drawings to streamline contractor activities and minimize disruptions to ongoing operation.

Results

The project contributed to a significant boost in production output, efficiency, and operational reliability, reducing bottlenecks and ensuring consistent output.  

• Increased Production Capacity: The expansion enabled the facility to produce 30 million pizzas annually, a 30% increase in capacity. 

• Operational Flexibility: Modular design allowed phased implementation, ensuring minimal downtime during transitions. 

• Cost Management: Delivered within the agreed budget, leveraging a time-and-material, not-to-exceed billing structure. 

• Strategic Growth: Positioned the facility to support long-term growth with built-in scalability.