Frozen Ready-to-Eat Meat Production Facility
Overview
To meet increasing production demands and reduce maintenance costs, the client needed to modernize their frozen Ready-to-Eat meat production capabilities. This project involved consolidating two outdated facilities into a single, state-of-the-art, USDA-approved facility to improve efficiency, streamline operations, and ensure regulatory compliance.
Approach
Led the $40MM construction of a new 85,000-sq. ft. USDA-approved production facility. Overseeing facility design, process design and validation, and packaging qualification, we ensured that all elements aligned with regulatory standards. A team of 30 was managed to ensure that construction and operational specifications met strict guidelines and timelines.
Key Contributions
Effectively managed a smooth exit from two outdated facilities by carefully transitioning $1MM in materials inventory with zero write-offs. By consolidating operations into a single facility, we reduced long-term maintenance costs and streamlined processes. We introduced improved process control and validation, enhancing both product quality and regulatory compliance.
Impact
The new facility enabled the client to boost production capacity and efficiency, significantly reducing downtime and operational bottlenecks. Consolidated operations cut overhead costs, positioning the client for sustainable growth. The strategic transition plan ensured that ongoing production was minimally disrupted, maximizing operational stability.